Gearbox Manual

Service
Workshop Manual
Golf 2017 ➤
Golf Variant 2017 ➤
7-speed dual clutch gearbox 0GC, Volkswagen R
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Service Department. Technical Information

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List of Workshop Manual Repair Groups
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Repair Group
00 - Technical data
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30 - Clutch
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34 - Controls, housing
35 - Gears, shafts
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39 - Final drive - differential

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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2018 Volkswagen AG, Wolfsburg D4B807111A7

Golf 2017 ➤ , Golf Variant 2017 ➤
7-speed dual clutch gearbox 0GC, Volkswagen R GmbH - Edition 02.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 General safety provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 2
1.3 Notes on tow-starting/towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Safety precautions when using testers and measuring instruments during a road test . . . . 2
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.5 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 Allocation gearbox - engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.1 Overview of fitting locations - electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
30 - Clutch . . . . . . . . . . . . . . . a.g.en.A.G.. V.o.lks.w.ag. e.n .AG. d.o. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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1.1 Assembly overvieworis - dual clutch . . . . . . . . . . . . . . . . .an.te.e . . . . . . . . . . . . . . . . . . . . . . . . . 10
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1.2 Removing sandau installing clutch end cover . . . . . . . . . . . . . .r a.c . . . . . . . . . . . . . . . . . . . . . . . 10
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1.3 Removing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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1.4 Installing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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1 Mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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1.1 Assembly overview - mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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1.2 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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1.3 Removing and installing mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2 Bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.1 Assembly overview - bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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2.2 Removing bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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2.3 Installing bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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3.1 Assembly overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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3.2 Emergency release from position P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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3.3 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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3.4 Moving push-button in the handle to installation position . . . . . . . . . . . . . . . . . . . . . . . . . . 41

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3.5 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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3.6 Removing and installing gear selector cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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3.7 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3.8 Checking and adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
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3.9 Renewing oil seal for selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.1 Specified torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.2 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.3 Install gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Contents i
6 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
7 Installing to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
8 Gear oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.1 Assembly overview - gear oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.2 Removing and installing gear oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.3 Removing and installing gear oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.4 Removing and installing motor for auxiliary hydraulic pump 1 for gearbox oil V475 . . . . . . 73
9 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
9.1 Overview of oil drain and inspection plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
9.2 Tools for gear oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
9.3 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
9.4 Draining and filling gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1 Currently, no repairs can be made to gears and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

1 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1.1 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1.2 Draining and filling gear oil . . . . n. A. G. ..V.o.lk.sw. a. g.e.n.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
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2 Oil seals . . . . . . . . . . . y.V.o.lk.s . . . . . . . . . . . . . . . . . . . s. n.o.t g.u. . . . . . . . . . . . . . . . . . . . . . . . . . 89
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2.2 Renewing left oilauseal
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2.3 Renewing rights oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 ce
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3 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 an
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3.1 Removing and installing right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
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4 Components of bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

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4.1 Assembly overview - components of bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

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4.2 Renewing right oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

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4.3 Renewing left oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

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4.4 Renewing needle bearing for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

4.5 Removing and installing output flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
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ii Contents
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1 Safety information
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(VRL011416; Edition 02.2018)
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⇒ “1.1 General safety provisions”, page 1
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⇒ “1.2 Safety measures when working on vehicles with a start/
stop system”, page 2
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⇒ “1.3 Notes on tow-starting/towing”, page 2
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⇒ “1.4 Safety precautions when using testers and measuring in‐

struments during a road test”, page 2
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1.1 General safety provisions

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To prevent personal injury and material damage to the vehicle,
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observe the following:

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♦ Before working on vehicle with engine running, move se‐
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lector lever into position “P” and apply handbrake.
To prevent personal injury and damage to or destruction of elec‐

trical and electronic components, observe the following:
♦ Connect and disconnect measuring and testing devices only
with the ignition switched off.
Caution
To prevent damage to the electronic components when dis‐

connecting the battery:
♦ Observe the necessary measures when disconnecting the
battery.
♦ Disconnect battery only after the ignition has been switch‐
ed off.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

Disconnecting and reconnecting battery .
1. Safety information 1
1.2 Safety measures when working on ve‐

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

with start/stop system.
♦ In vehicles with the start/stop system activated (identifia‐
ble by an indication in the dash panel insert) the engine
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1.3 Notes on tow-starting/towing
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Danger of irreparable damage to gearbox.
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♦ If the vehicle must be towed, the selector lever must be in
the “N” position, and the vehicle must be towed at a speed
no greater than 50 km/h and for a distance not exceeding
50 km.
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It is not possible to tow-start the engine, e.g. if the battery is too tion in
flat or the starter is not functioning.
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1.4 Safety precautions when using testers

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

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

Please note the following to avoid personal injury and damage to,
or destruction of, electrical and electronic components:
♦ Connect and disconnect measuring and testing devices only
with the ignition switched off.
Caution
To prevent damage to the electronic components when dis‐

connecting the battery:
♦ Observe the necessary measures when disconnecting the
battery.
♦ Disconnect battery only after. Vthe ignition has been switch‐
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– Disconnectau battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
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Disconnecting
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1. Safety information 3
2 Identification
⇒ “2.1 Gearbox identification”, page 4
2.1 Gearbox identification

The gearbox code can be found on top of the gearbox, near the
starter.
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The gearbox codes can be found on top of the gearbox.

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♦ PVQ = gearbox code.
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♦ 28.09.14 = production date 28 September 2014.
♦ The remaining data are production-specific.
Note
The gearbox code is also indicated on the vehicle data stickers.

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

Gear oil
The “0GC” dual clutch gearbox only has one oil system.
The oil system lubricates the gears, shafts, final drives, clutches
and mechatronic unit for dual clutch gearbox - J743- .
Only use gear oil in accordance with ⇒ Electronic parts catalogue
(ETKA) .
Gear oil filter change - »Yes or no?«
• The gear oil filter does not have to be changed as a matter of
course.
Do not change the filter if:
♦ The gear oil cooler or its O-rings were renewed and no coolant
has got into the oil.
♦ Seals and O-rings of the gearbox were renewed.
♦ The sump or mechatronic unit were renewed.
♦ The service interval was reached.
Filter must be changed if: agen
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♦ Metal particles have d b been found in the oil.
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♦ The clutch isauburnt
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3.2 Rules for cleanliness
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♦ First thoroughly clean connecting points and surrounding

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areas and then loosen bolts.

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♦ Seal open lines and connections immediately using clean

, is n
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plugs or sealing caps from engine bung set - VAS 6122- .

hole
spec
♦ Place removed parts on a clean surface and cover them to

es, in part or in w
t to the co
prevent them from getting dirty. Use sheeting and paper for
this purpose. Use lint-free cloths only.
♦ Make sure that no dirt can enter an »open« gearbox.
rrectness of i
♦ Install only clean parts; do not remove Genuine parts from

l purpos
packaging until immediately before installing.

♦ If repair work cannot be performed immediately, cover opened
nform
ercia
parts carefully.
m
at
om
♦ Protect disconnected electrical connectors from dirt and water,

ion
c
and reconnect them only when dry.

in t
or
his
ate
3.3 General repair instructions

do
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To ensure flawless and successful gearbox repairs, the greatest

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care and cleanliness as well as the use of good and proper tools Cop py
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are essential. Also note the basic rules on safety when performing yri
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3. Repair instructions 5
A number of general notes on the individual repair procedures,

which can otherwise be found in the relevant sections of the man‐
ual, are summarised here. They apply for this particular workshop
manual.
Guided fault-finding, vehicle self-diagnosis and test instruments
♦ Before performing repairs to the gearbox, determine the cause
of the fault as accurately as possible ⇒ Vehicle diagnostic
tester, Guided Fault Finding , Vehicle Self-Diagnosis
or Test Instruments .
Special tool
For a complete list of special tools used in this workshop manual,
see ⇒ "Workshop equipment and special tools" .
Gearbox
Always make sure that no dirt can enter an »open« gearbox. In
particular, dirt entering an »exposed« mechatronic unit for dual
clutch gearbox - J743- and/or oil pump can lead to gearbox failure.
♦ If gearbox covers have been unbolted or gearbox has no fluid,
do not run engine or tow vehicle.
♦ First thoroughly clean connecting points and surrounding
areas and then loosen bolts.
♦ When installing the gearbox, ensure that dowel sleeves be‐
tween the engine and gearbox are correctly located.
Locking devices . Volkswagen AG
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♦ Do not overstretch retaining rings. y V olk not
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♦ Always renew retaining rings whichhoris
have been damaged or nte
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overstretched. aut ra
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♦ Retaining rings must locate properly in grooves.

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nl
pt
du
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3.4 Gaskets and seals

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ility
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♦ Renew O-rings, seals and gaskets.

wit
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♦ After removing gaskets and seals, always inspect contact sur‐

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

es, in part or in w
other signs of damage.

t to the co
♦ Before installing seals, lightly oil outer diameter and half-fill

space between sealing lips -arrow- with sealing grease -
rrectness of i
G 052 128 A1- .

l purpos
♦ The open side of the oil seals faces toward the side with fluid
filling.
nf
ercia
♦ Only use DSG transmission oil. Other lubricants will cause

or
problems in function.
m
m
atio
om
♦ Coat O-rings with DSG gear oil to prevent pinching of rings

n in
or c
during assembly.
thi
te
sd
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♦ After renewing gaskets, O-rings and seals, check oil level in

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gearbox and top up if necessary ⇒ page 75 .

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ut or
7-speed dual clutch
ss a gearbox 0GC, Volkswagen R GmbH - Edition 02.2018
ac
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3.5 Nuts and bolts
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itte
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♦ Loosen and tighten securing bolts and securing nut for covers
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and housings diagonally.
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♦ Specified torques given are for unoiled nuts, bolts and screws.
ole,
spec
♦ Clean threads of bolts which are to be installed with locking
t to the co
fluid using a wire brush. Then insert bolts with locking fluid -
AMV 185 101 A1- .
♦ Use a thread chaser to clear residual locking fluid from all
rrectne
threaded holes into which self-locking bolts are to be screwed.
Otherwise there is a danger of bolts shearing when subse‐
ss
quently being removed.
o
cial p
f in
♦ Check pitch of thread, to ensure correct thread chaser is used
form
mer
to clean threads and to ensure the threads are not damaged.
atio
om
♦ Always renew self-locking bolts and nuts.
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3. Repair instructions 7
4 Technical data
⇒ “4.1 Allocation gearbox - engine”, page 8
⇒ “4.2 Capacities”, page 8
4.1 Allocation gearbox - engine

Dual clutch gearbox 7-speed 0GC, four-wheel drive
Codes SWQ RAT SKX
Manufactured from 05.17 11.16 11.16
to 01.2017
olkswagen AG 05.2017
en AG. V
wag2.0 d
Allocation Engine 2.0 l - Volks l - 213/228 KW oes n2.0
ot g l - 213/228 KW
213/215/228se
d KW
by ua
ran
ri tee
tho or
Glean following data from ⇒ Electronic partss catalogue
au (ETKA) . ac
s
ce
♦ Individual gear ratios
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un
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♦ Gear oil
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♦ Clutch allocation
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4.2 Capacities
es, in part or in w
t to the co
Capacity Dual clutch gearbox 0GC
rrectness of i
Initial filling 6.8 l ± 0.1 l
Changing approx. 6 l
l purpos
♦ Change interval: ⇒ Maintenance manual and/

or ⇒ service tables “ELSA”
nform
ercia
Lubricant DSG transmission oil

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tion in
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Capacity Front bevel box
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Initial filling approx. 0.85 l

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Changing Filled for life, no change C py
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Lubricant Gear oil p by
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The oil is available as a replacement part; part no. ⇒ Electronic
AG.
parts catalogue (ETKA) .

Further information in the part number designates the container
size.

5 Electrical components
⇒ “5.1 Overview of fitting locations - electrical components”, page
9
5.1 Overview of fitting locations - electrical components
1 - Mechatronic unit for dual

clutch gearbox - J743-
❑ Bolted onto front of
gearbox housing
❑ Removing and installing
⇒ page 28
2 - Selector lever - E313-
❑ With selector lever sen‐
sors control unit - J587- ,
selector lever lock sole‐
noid - N110- and selec‐
tor lever locked in posi‐
tion P switch - F319- n AG. Volkswagen AG do
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❑ The components are in‐ byV
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ua
tegrated in the printed ir se
d ran
tee
circuit of the shift unit; utho
or
they cannot be renewed ss
a ac
separately.
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❑ Checking ⇒ vehicle di‐
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itte
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agnostic tester
rm
ab
pe
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selector mechanism
, is n
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⇒ page 42
hole
spec
3 - Gearbox
es, in part or in w
t to the co
⇒ page 54
rrectness of i
l purpos
nform
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tion in
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5. Electrical components 9
30 – Clutch
1 Clutch
⇒ “1.1 Assembly overview - dual clutch”, page 10
⇒ “1.2 Removing and installing clutch end cover”, page 10
⇒ “1.3 Removing dual clutch”, page 14
⇒ “1.4 Installing dual clutch”, page 17
1.1 Assembly overview - dual clutch

Replacement parts
1 - Retaining ring for dual AG. Volkswagen AG d

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❑ Renew after removal ised b ara
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2 - Retaining ring for dual s aut ra
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clutch s
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un
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❑ Renew after removal
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3 - Retaining ring for drive plate
erm
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4 - Dual clutch
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❑ Removing ⇒ page 14
ole,
spec
❑ Installing ⇒ page 17
t to the co
5 - Shims
❑ 10 shims having differ‐
ent »thicknesses«.
rrectne
They are sized in
0.05 mm increments.
ss
❑ Thickness of spacer ring

o
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must be determined
nform
when installing dual

mer
clutch.
atio
om
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c
6 - Dual clutch end cover

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um
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fo
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⇒ page 10
t.
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1.2 Removing and installing clutch end cov‐

er
Special tools and workshop equipment required
10 Rep. gr.30 - Clutch

♦ Clean assembly sleeve - T10459- before using. Do not use a

scratched sleeve.
Removing
• Cover and retaining ring must always be renewed.
– Drain gear oil ⇒ page 75 .
– Remove gearbox ⇒ page 54 .
– Secure gearbox in a vertical position on engine and gearbox
support ⇒ page 68 .
– Renew gear oil filter ⇒ page 72 .
– Lever out retaining ring -2- of clutch end cover using screw‐
driver -1- -arrow- and remove.
AG. Volkswagen AG d
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es, in part or in w
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1. Clutch 11
– Lever off clutch end cover -2- through side opening in housing
using a screwdriver -1- or tyre lever -arrow- and remove clutch
end cover.
• The original clutch end cover and circlip must not be re-instal‐
led after removal.
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is n
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spec
Installing
t to the co
Caution
rrectne
Cover and retaining ring must always be renewed.
Never grasp a new cover in centre seal. The centre hole of the
ss
cover must not be touched, oiled or brought into contact with
o
cial p
f
other materials. Leaks will result.
inform
mer
Never install new covers with a hammer!
atio
om
n
c
i
or
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te
sd
iva
o
r
– Handle cover only as shown -in this picture-.

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There must be no stickers on the inside of the cover. If, however, cted agen
Prote AG.
stickers are present, remove them carefully.
– The running surface on the end of the shaft of the clutch

-arrow- must be free of oil and dry.
– If necessary, thoroughly clean running surface.
WARNING
The centre seal of the new cover must be »preformed« before

installing:

AG. Volkswagen AG d Golf 2017 ➤ , Golf Variant 2017 ➤
agen
ksw 7-speed dual clutch gearbox 0GC, Volkswagen R GmbH - Edition 02.2018
oes
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– Clean assembly
ut
ho sleeve - T10459- “before using”. Do not e o use
a scratched
ss a sleeve. ra
c
ce
le
– Set sleeve on a flat surface.
un
pt
an
d
itte
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rm
ab
pe
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Guide cover horizontally and evenly over entire sleeve
l purpos
-as shown in this figure-. This will bring the sealing lip into in‐
stallation position.
nform
ercia
– Remove sleeve upwards out of cover and set sleeve on end

m
of clutch shaft.
a
com
tion in
– Moisten outer seal of cover with oil.
r
te o
thi
s
iva
do
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rp
c
Caution
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fo
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t.
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Moisten only the outer seal of the cover with oil. Oiling the inner
Cop py
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seal will always cause leaks. opyri
gh by
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by c lksw
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Prote AG.
– Guide cover horizontally over sleeve and press evenly onto its
seat.
Caution
Work carefully. Any sort of blow to the cover is certain to cause

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

-screwdriver- until »new« retaining ring can be installed.
– Install new retaining ring.
1. Clutch 13
– Do not remove bush until retaining ring is installed.

– Install gearbox ⇒ page 62 .
– Fill with gear oil ⇒ page 80 .
WARNING
Do not start engine if there is no oil in gearbox.
. Volkswagen AG
gen AG does
– After installation of gearbox, initiate default settings olkby
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means of Guided Functions ⇒ vehicle diagnostic se
d tester .
b ara
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1.3 Removing dual clutch ss c
ce
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nl
pt
du
an
itte
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erm
ab
♦ 2 x hooks - 3438-
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
io
♦ Puller - T10055-
n
c
in t
or
his
ate
do
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cum
for
en
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Prote AG.
♦ Puller - T10525-
Brief description
• The axial play of the clutch is readjusted during installation
procedure.

• To remove or install clutch, gearbox must be securely attached

to an assembly stand in vertical position ⇒ page 68 . Only
this way is it possible later to adjust axial play of the clutch
without error.
Removing
– Remove clutch end cover ⇒ page 10 .
Important! Installation location of drive plate
– Check that marking on drive plate -arrow- aligns with the mark‐
ing on the outer plate carrier.
AG. Volkswagen AG d
If there is no marking: agen oes
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ara
– Mark installation position of drive plate ris relative to periphery of
ed
nte
outer plate carrier with permanent autmarker, as shown in illus‐
ho eo
ra
tration. ss c
ce
e
nl
• During installation, drive plate must always be repositioned at
pt
du
an
itte
marked position.
y li
erm
ab
ility
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Note
h re
hole
spec
The retaining ring is renewed together with the clutch. If the clutch
es, in part or in w
which is removed is reinstalled, the securing ring is to be used
t to the co
again as well.
rrectness of i
– Lever out retaining ring -2- of drive plate using screwdriver
l purpos
-1- -arrow-.
nf
ercia
orm
m
atio
om
n in
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Prote AG.
1. Clutch 15
– Apply puller - T10525- together with puller - T10055- on

splines and carefully pull drive plate off its seat -arrows-.
– Remove retaining ring -arrow- and save it for now.

AG. Volkswagen AG d
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lksw not
Note by Vo gu
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Do not dispose of the retaining ring yet because it will be sneeded
th
au ra
to measure axial clearance. s c
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nl
pt
du
an
itte
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erm
ab
ility
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es, in part or in w
– Remove shim -arrow-.
t to the co
Caution
rrectness of i
Carefully remove the dual clutch. Take care that no parts fall
l purpos
out. Therefore, do not turn the clutch over!
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
– Engage 2 hooks - 3438- on opposite sides of clutch -arrow-.

en
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t.
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Prote AG.

– Remove dual clutch using hooks - 3438- .
AG. Volkswagen AG d
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itte
1.4 Installing dual clutch
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♦ Universal dial gauge holder - VW 387-
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
♦ Dial gauge - VAS 6079-

r
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Prote AG.
♦ Retaining pins - T10524-
1. Clutch 17
♦ Thrust piece - T10526-
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Caution
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pt
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♦ The drive plate has to remain engaged between the teeth
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erm
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of the outer plate carrier.
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♦ If the drive plate detaches, the plates in the dual clutch can
wit
, is n
h re
shift. It may then not be possible to adjust the clutch cor‐
hole
rectly when it is installed.
spec
es, in part or in w
t to the co
♦ Do not lift (not even slightly) or remove plate carrier! The
plates could turn.
rrectness of i
Brief description
l purpos
• To remove or install the clutch, the gearbox must be securely

attached to an assembly stand in vertical position.
nform
ercia
• The large plate carrier goes through all plates inside the clutch.
m
at
It must not slip out of the lowest plate.

om
ion
c
in t
r
Installing
o
his
ate
do
riv
– Take great care when removing the dual clutch from its pack‐
p
cum
or
age.
f
en
ng
t.
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– Turn piston rings by hand. They must move freely and must Cop py
. rig
not bind.
t
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cted agen
Prote AG.
– Ensure that piston rings -1-, -2-, -3- and -4- are seated cor‐
rectly. The ring butts -arrows- of piston rings -1- and -3- should
align.
– The ring butts -arrows- of piston rings -2- and -4- should align
and be offset 180° to the ring butts of piston rings -1- and -3-.

Important! Position of drive plate

– Before installing, check if there is a marking -arrow- on dual
clutch.
– If there is no marking, use a permanent marker to make a col‐
our marking on the drive plate and one the outer plate carrier.
– Insert retaining pin - T10524- -1-.

• The retaining pin - T10524- should be held by a second me‐
chanic while the dual clutch is being inserted.
– Carefully insert -dual clutch-, ensuring it does not fall.

– If necessary, insert clutch by turning slightly.
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
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tho eo
au ra
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nl
pt
du
an
itte
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The dual clutch is properly fitted if there is almost no play in the

ility
ot p
retaining pin - T10524- .

wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
♦ The retaining pin remains inserted until the clutch end cover
is installed.
rrectness of i
♦ The dual clutch must now not be rotated any more, as this can
l purpos
shift the position of the retaining pin - T10524- .

nf
ercia
orm
m
atio
om
n in
or c
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1. Clutch 19
– Lever out retaining ring -2- of drive plate using screwdriver

-1- -arrow-.
wage
Note yV
olks es n
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d b ua
ran
ir se te
This retainingutring
ho will be used again. Do not dispose of it. e or
a ac
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
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, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Apply puller - T10525- together with puller - T10055- on

splines and carefully pull drive plate off its seat -arrows-.
nform
mercia
a
com
Note tion in
r
te o
thi
The retaining pin - T10524- must be held by a second mechanic

s
iva
do
r
while pulling off.

rp
cum
fo
en
ng
t.
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– Carefully remove drive plate from dual clutch -arrows- and Cop py
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place it on one side. opyri
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Caution
AG.
Do not lift (not even slightly) or remove plate carrier! The plates
could turn.
Determining shim for dual clutch:

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

Before this ring is finally disposed of, 3 measurements must be
made.
First measurement (axial play of shaft)
– Screw universal dial gauge - VW 387- to gearbox flange.

– Set -tip of dial gauge- on input shaft.

– Set -dial gauge- to 0 with preload.
– Lift dual clutch with force -in direction of arrow- to stop using
hooks - 3438- and note measurement.
– Call this value “A”.
Note AG. Volkswagen AG d

agen oes
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This value will be needed later for the checkemeasurement so gu
ara
d
save value “A” until the last measurement hohas
ris
been performed. nte
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ss c
Second measurement
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le
un
pt
an
d

itte
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rm
ab
pe
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
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cum
fo
en
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t.
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Cop py
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Prote AG.
1. Clutch 21
– Set tip of dial gauge -on hub of large plate carrier-.
Note
Tip must not sit on retaining ring.
– Set -dial gauge- to 0 with preload again.

– Lift dual clutch with force to stop and note measurement.
– Call this value “B”.
Now calculate which shim must be fitted:
– Use this formula:
Value “B” minus value “A” minus 0.11 = thickness of shim to
be fitted.
– Note result.
The shims are sized in 0.05 mm increments.
– Measure the shims and determine which one is closest to the
result.
WARNING
Always use the next-largest shim, never the next-smallest.

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– Set tip of dial gauge -on hub of large plate carrier-.
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– Install new retaining ring -arrow-.
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1. Clutch 23
– Fit drive plate into dual clutch.

• When installing, check if marking on drive plate is aligned with
marking on outer plate carrier -arrows-. If the markings were
subsequently make, align these.
– A second mechanic must hold retaining pin - T10524- in its
place and press outwards slightly.
– Carefully drive the drive plate onto its seat using press tool -
40-21- and a plastic hammer.
– Install drive plate retaining ring.
– Starting at the opening, press retaining ring in clockwise di‐
rection into its fitting position.
• The retaining ring must be fully engaged.
– Use screwdriver to check that retaining ring is correctly seated
and engaged.
– Now remove retaining pin - T10524- from between dual clutch
and housing.
– Install clutch end cover ⇒ page 10 .
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34 – Controls, housing
1 Mechatronic unit
⇒ “1.1 Assembly overview - mechatronic unit”, page 25
⇒ “1.2 Removing and installing sump”, page 26
⇒ “1.3 Removing and installing mechatronic unit”, page 28
1.1 Assembly overview - mechatronic unit
1 - Gearbox
2 - Mechatronic unit for dual
clutch gearbox - J743-
⇒ page 28
3 - Bolt
❑ Tightening sequence
⇒ page 26
4 - Seal
5 - Bolts
❑ Qty. 4
❑ 8 Nm +60°
6 - Retaining clip
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1. Mechatronic unit 25
Mechatronic unit for dual clutch gearbox - J743- - specified torque

and tightening sequence
• Renew bolts after removing.
– Tighten bolts in 3 stages in the sequence shown:
Stage Bolts Specified torque/turning further angle
1. -1…9- Screw aingeby hand
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1.2 Removing and installing sump
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♦ Used oil collector and extractor - VAS 6622 A-
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♦ Engine bung set - VAS 6122-
26 Rep. gr.34 - Controls, housing

♦ Torque wrench - V.A.G 1410-
Removing
– Move selector lever to position “P”.
Always make sure that no dirt can enter an »open« gearbox.
Caution
Risk of damage to gearbox.

♦ Do not run engine or tow vehicle with sump removed or
when there is no gear oil in the gearbox.
– Remove noise insulation ⇒ General body repairs, exterior;

Rep. gr. 66 ; Noise insulation; Removing and installing noise
insulation .
– Remove connecting hose between charge air cooler and
charge air pipe ⇒ Rep. gr. 21 ; Charge air system; Assembly
overview - charge air system .
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– Remove electrical wiring and retainers from sump at front

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

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Caution
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♦ Do not touch contacts of mechatronic connector with the

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– Release rotary locking mechanism of connector for mecha‐

tronic unit by turning in direction of starter -arrow- and pull off
connector.
– Place used oil collection and extraction unit - VAS 6622- below
gearbox.
– Remove securing clip -3-.
– Unscrew bolts -1- diagonally and remove.
– Remove sump -2-. If necessary, lightly strike sump with a rub‐
ber-headed hammer to loosen.
Installing
Install in reverse order of removal, observing the following:
• Always renew the sump, the sump

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When renewing the mechatronic unit for dual clutch gearbox -

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– Remove any oil and grease from sealing surface on gearbox

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housing.
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– Bring sump -2- into position and tighten new bolts -1- diago‐
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nally in several stages.

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• When positioning the sump, ensure that no cable connections

are trapped.
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– Install new securing clip -3-.

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• Offset side of retaining clip faces gearbox.

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– Fit connector for mechatronic unit and engage.

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– Top up gear oil and check gear oil level ⇒ page 75 .

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unit

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Always make sure that no dirt can enter an »open« gearbox.
In particular, dirt entering an »exposed« mechatronic unit and/or
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The mechatronic unit can stick on the dowel pinsorwhen
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– Remove sump ⇒ page 26 .
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– Unscrew bolts -arrows- in a diagonal sequence.
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– Remove mechatronic unit -1- carefully.
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Holding and carrying mechatronic unit

– Remove mechatronic unit for dual clutch gearbox - J743- .
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Laying mechatronic unit to side properly
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– Put down mechatronic unit so that sensors -arrows- are point‐
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Installing
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• Renew O-ring -arrow- on connector for mechatronic unit for
ion
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dual clutch gearbox - J743- .

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– Carefully insert mechatronic unit -1- into gearbox.

– Tighten bolts -arrows- of mechatronic unit for dual clutch gear‐
box - J743- ⇒ page 26 .
– Install sump ⇒ page 26 .

– Top up gear oil and check gear oil level ⇒ page 75 .
– Adopt basic setting for mechatronic unit:
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♦ 02 Gearbox electronics sa
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♦ 02- Basic setting
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2 Bevel box
⇒ “2.1 Assembly overview - bevel box”, page 32
⇒ “2.2 Removing bevel box”, page 33
⇒ “2.3 Installing bevel box”, page 35
2.1 Assembly overview - bevel box
1 - Bolt
❑ 25 Nm
2 - Heat shield
❑ For drive shaft.
3 - Nuts
❑ Qty. 2
❑ Specified torque ⇒ Run‐
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7 - Bevel box
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8 - Bolts
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❑ Qty. 4
❑ 40 Nm +90°
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9 - Bevel box carrier

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❑ Bevel box carrier to bevel box
AG.
❑ Specified torque and tightening sequence: ⇒ page 36

11 - Bolts
❑ Qty. 2
❑ Bevel box carrier to engine
❑ Specified torque and tightening sequence: ⇒ page 36

2.2 Removing bevel box

♦ Socket insert - T10107 A-
♦ Used oil collector and extractor - VAS 6622 A-
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♦ Hexagon key extension, 8 mm - 3247-
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♦ Grease for clutch plate splines ⇒ Electronic Parts Catalogue

(ETKA)
2. Bevel box 33
Golf 2017 ➤ , Golf Variant 2017 ➤ olkswagen AG
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– Remove subframe without steering rack ⇒ Running gear,
ss c
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axles, steering; Rep. gr. 40 ; Subframe; Removing and instal‐
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– Remove front exhaust pipe with catalytic converter ⇒ Rep. gr.
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– Remove right drive shaft ⇒ Running gear, axles, steering;
es, in part or in w
Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .
t to the co
– Unscrew bolts -A- and -B- from bevel box and remove heat
shield -1-.
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– Remove countersunk bolt for right flange shaft with socket -

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– To do this, screw 2 boltsss into flange and counterhold flange
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– Remove bolts -arrows- for bevel box to gearbox.
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– Pull bevel box together with flange shaft towards right and off
gearbox.
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– Install bevel box ⇒ page 35 .
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2.3 Installing bevel box
Note
♦ Refer to section “Removing bevel box” for required special

tools ⇒ page 33 .
♦ All cable ties which were opened or cut during removal must
be renewed at the same points.
♦ Lightly grease the splines of the flange shaft using grease for
clutch plate splines .
Installing
– Push bevel box together with flange shaft onto gearbox while
turning flange shaft.
Note
Do not use securing bolts to pull bevel box onto gearbox, or bevel
box will cant and bolt holes can break off.
– Bolt bevel box onto gearbox using 4 new bolts. Specified tor‐
que ⇒ Item 8 (page 32) .
2. Bevel box 35
– Screw in bolts -1- and -2- for securing bevel box bracket hand-
tight.
– Observe correct tightening sequence:
1- Tighten bolts -2-.
2- Tighten bolts -1-.
– Secure flange shaft with new countersunk bolt. Specified tor‐

que: ⇒ Item 1 (page 32)
– Check oil level in bevel box and top up ⇒ page 84 .
Specified torques
Component Specified torque

Securing bolts for bevel box bracket agen
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3 Selector mechanism
⇒ “3.1 Assembly overview - selector mechanism”, page 37
⇒ “3.2 Emergency release from position P”, page 38
⇒ “3.3 Removing and installing selector lever handle”,
page 39
⇒ “3.4 Moving push-button in the handle to installation position”,
page 41
⇒ “3.5 Removing and installing selector mechanism”, page 42
⇒ “3.6 Removing and installing gear selector cable”, page 46
⇒ “3.7 Checking selector mechanism”, page 48
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⇒ “3.8 Checking and adjusting not 49
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3.1 Assembly overview - selector mechanism
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⇒ page 39
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⇒ page 42
4 - Securing clip
5 - Nut
❑ For selector mechanism
to body
❑ Qty. 4
❑ 8 Nm
6 - Selector lever cable
❑ Selector lever cable is
not greased
❑ Removing and installing ⇒ page 46
❑ Checking and adjusting ⇒ page 49
3. Selector mechanism 37
7 - Bolt
❑ Adjuster screw for selector lever cable
❑ 13 Nm
8 - Cover
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12 - Grommet
❑ Clip in on cable support bracket
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❑ For cable support bracket mounting on gearbox
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13 - Spacer
❑ Installation position: larger diameter faces gearbox
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14 - Nut
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Do not remove knob.

– Open lid of storage compartment.
– Grasp under selector lever cover with one hand, and unclip
cover by pulling it upwards.
– Depress brake pedal or set handbrake.
– Push selector cover to one side.
– Using a screw driver, from right side, press yellow plastic part
and hold in this position.
Selector lever can now be moved from position »P«.

3.3 Removing and installing selector lever

handle
♦ Hose clip pliers - V.A.G 1275-
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Brief description
ole,
spec
Handle is removed together with selector cover.
t to the co
Removing
– Shift selector lever to position “D”.
rrectne
The push button -arrow- does not need to be pulled out by hand.
Push button engages automatically in installation position when
ss
handle is pulled off.
o
cial p
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– Open lid of storage compartment. Prote AG.
– Grasp under selector lever cover with one hand, and unclip
cover by pulling it upwards.
– Separate electrical connector.
– Cut open clamp -arrow- under boot using side cutters.

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

possible to install the handle.
Installing
• Selector lever is in position “D”.
AG. Volkswagen AG d
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♦ It might be possible for the push-button to be pressed into the C py
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handle. Never install a handle with the push-button pressed
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Prote AG.
♦ Move push-button to installation position ⇒ page 41 .
♦ New handle is supplied with installation guard. Do not remove
guard until just before installing. To remove, pull out
-in direction of arrow-.

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

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

after being pressed. If this happens, pull handle off again and
move push button to installation position again ⇒ page 41 . Then
fit the handle again.
– If the press button moves back to its start position, the clamp
can be tightened using the hose clip pliers - V.A.G 1275- .
– Connect electrical connector.
– Clip cover in position.
3.4 Moving push-button in the handle to in‐

stallation position
If the button was pressed by mistake, the installation position can
be restored.
There are 2 ways of moving the push button into the installation
position, »with« and »without« installation guard. Both of them are
agen
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Place handle »with« installation guard in installation
or position:
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When using the installation guard, make sure that ss it has an eyelet
a ac
-arrow- at the front. Other types of installation guard are not suit‐
ce
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un
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able.
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rrectnes
– Holding down push button, completely push in installation

s o
guard with eyelet -arrow- until installation guard engages, then

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release push button. When the installation guard is pulled out,

form
mer
the push-button engages in the installation position.

atio
om
Place handle »without« installation guard in installation position:

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– Carefully unclip handle trim -A- upwards.
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– Using e.g. a screwdriver press small lever -1- for pull rod into
h re
groove -2-. This action presses the push button -3- back into
hole
spec
installation position.
es, in part or in w
t to the co
-I- = button pressed in
-II- = button in installation position
rrectness of i
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Note
nform
ercia
♦ Press the lever only into the groove and no further.

m
♦ Do not clip the handle trim onto selector mechanism until the
at
om
io
handle has been fitted. This makes it possible to check wheth‐
n
c
in t
r
er the small lever engages in the pull rod when the push-button
o
his
te
is pressed.
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3.5 Removing and installing selector mech‐
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⇒ “3.5.1 Removing and installing selector mechanism with selec‐ Prote AG.
tor lever cable”, page 42
⇒ “3.5.2 Removing and installing selector mechanism without se‐
lector lever cable”, page 44
3.5.1 Removing and installing selector mech‐

anism with selector lever cable

AG. Volkswagen AG d
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dual clutch gearbox 0GC, Volkswagen
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utho eo
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♦ Release lever - 80-200-
ss
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Brief description
nf
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In the interior, the centre console must be removed.
orm
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The heat shield beneath the vehicle must be removed.
om
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Removing
thi
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– Remove selector lever handle ⇒ page 39 .
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– Remove centre console ⇒ General body repairs, interior; Rep.

t.
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gr. 68 ; Centre console; Removing and installing centre con‐ Cop py
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sole . opyri
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– If fitted, remove footwell air duct ⇒ Heating, air conditioning;
by lksw
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Rep. gr. 87 ; Air duct; Assembly overview - air routing and air
AG.
distribution in passenger compartment .

– Separate electrical connector from selector mechanism to ve‐
hicle wiring harness.
– Remove air filter housing ⇒ Rep. gr. 24 ; Air filter; Removing
and installing air filter housing
– Push ball socket -1- of selector lever cable off gearbox selector
lever using removal lever - 80-200- .
– Unscrew bolts -2- for cable support bracket.
– Do not bend or kink cable.
– Install centre tunnel heat shield below selector mechanism ⇒
General body repairs, exterior; Rep. gr. 66 ; Mouldings/trims/
extensions; Removing and installing floor heat shield .
– Remove bracket -A- if present.

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

♦ Do not grease selector lever cable. AG. Volkswagen
n AG do
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♦ Following installation of selector
by
Volks mechanism, selector leverot g
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cable must be checkedrisfor
ed ease of movement and be adjusted. ran
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– Install heat shields below selector mechanism ⇒
s General body
ce
e
repairs, exterior; Rep. gr. 66 ; Mouldings/trims/extensions;

nl
pt
du
Removing and installing floor heat shield .
an
itte
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erm
ab
– If featured, install footwell air duct ⇒ Heating, air conditioning;
ility
ot p
wit
, is n
h re
hole
spec
– Install centre console ⇒ General body repairs, interior; Rep.
es, in part or in w
gr. 68 ; Centre console; Removing and installing centre con‐
t to the co
sole .
– Install selector lever handle ⇒ page 39 .
rrectness of i
– Adjust selector lever cable ⇒ page 49 .
l purpos
– Check selector mechanism ⇒ page 48 .

– Install air filter housing ⇒ Rep. gr. 24 ; Air filter; Removing
nf
ercia
and installing air filter housing .

rm
m
atio
m
Specified torques
o
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or c
♦ ⇒ “3.1 Assembly overview - selector mechanism”, page 37

thi
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3.5.2 Removing and installing selector mech‐

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anism without selector lever cable
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Brief description copy Vo
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Prote
In the interior, the centre console must be removed.
AG.
The heat shield beneath the vehicle must be removed.

Removing
– Remove selector lever handle ⇒ page 39 .
– Remove centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; Centre console; Removing and installing centre con‐
sole .
– If fitted, remove footwell air duct ⇒ Heating, air conditioning;
– Separate electrical connector from selector mechanism to ve‐
hicle wiring harness.
– Shift selector lever on selector mechanism to position “N”.


– Using a screwdriver lever the cover off from under the selector
mechanism -arrow-.
Note
It is not permissible to reuse the cover. Always renew after re‐

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

from the selector lever -arrows-.
– Remove securing clip -arrow-.

Always renew securing clip. agen
AG. Volkswagen AG d
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– Pull selector lever cable out of selector mechanism. ed by
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es, in part or in w
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Prote AG.
– Remove bracket -A- if present.

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

♦ Do not grease selector lever cable.
♦ Following installation of selector mechanism, selector lever
cable must be checked for ease of movement and be adjusted.
• Selector lever on selector mechanism must be set to position

“N”.
– Insert cable into selector mechanism, attach to selector lever
and fit new securing clip.
– Install heat shield below selector mechanism ⇒ General body
– If featured, install footwell air duct ⇒ Heating, air conditioning;
G. Volkswagen AG d
– Install centre console ⇒ General body repairs, interior;
lksw
ageRep.
nA oes
not
gr. 68 ; Centre console; Removing and installing
by centre con‐
Vo gu
ara
sole . ris
ed nte
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– Install selector lever handle ⇒ page 39
ss .
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c
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nl
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erm
ab
ility
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Specified torques
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hole
spec
es, in part or in w
3.6 Removing and installing gear selector

t to the co
cable
rrectness of i

l purpos

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om
ion
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ate
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Prote AG.

Removing
– Push ball socket -1- of selector lever cable off gearbox selector
lever using removal lever - 80-200- .
– Unscrew bolts -2- for cableAG
support
. Volkswabracket.
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olks
– Do not bend or kink
y V cable.
ot g
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– Shift selector thoris
lever on selector mechanism to position “N”.
tee On‐
or
ly in thiss auposition the selector lever cable can be released. ac
s
ce
le

un
pt
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d
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erm
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ility
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ole,
– Using a screwdriver lever the cover off from under the selector
spec
mechanism -arrow-.
t to the co
Note
rrectne
It is not permissible to reuse the cover. Always renew after re‐
s
moving.
s o
cial p
f inform
mer
atio
om
n
c
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or
n thi
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sd
iva
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– Release the cable as shown with a screwdriver, and pull off

p
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from the selector lever -arrows-.

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– Remove securing clip -arrow-.

Always renew securing clip.
– Pull cable out of selector mechanism and remove.
gen AG
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Installing y Vol gu
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Install in reverse order of removal, thobserving
o the following: eo
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Note
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ility
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♦ Do not grease selector lever cable.
h re
hole
spec
♦ Following installation, selector lever cable must be checked
es, in part or in w
for ease of movement and be adjusted.
t to the co
• Selector lever on selector mechanism must be set to position
“N”.
rrectness of i
– Insert cable into selector mechanism, attach to selector lever
l purpos
and fit new securing clip.

– Install heat shield below selector mechanism ⇒ General body
nf
ercia
o
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atio
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– Bring selector lever cable with cable support bracket into po‐
thi
te
sd
a
sition and tighten with bolts -2-.

iv
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m
– Do not press ball head -1- of selector lever cable onto gearbox
f
en
ng
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selector lever yet. Wait until selector lever cable has been
Co
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checked and adjusted. t. C rig
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– Check and adjust selector lever cable ⇒ page 49 .
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Prote AG.
3.7 Checking selector mechanism

The starter must not operate in the selector lever positions “R”,
“D” and “S” and in the Tiptronic position.
On right-hand drive vehicles, the starter must operate in selector
lever positions “P” and “N” only when the push-button in the se‐
lector lever handle is not pressed.
Above 5 km/h:
When the selector lever is shifted to “N”, the selector lever lock
solenoid must not lock the selector lever. Selector lever can be
shifted back into a driving range.
Below 5 km/h:
When the selector lever is shifted to “N”, the selector lever lock
solenoid must lock the selector lever only after approx. 1 second.
Selector lever cannot be shifted out of “N” position until brake
pedal is depressed.
Selector lever in “P” position and ignition switched on
• Brake pedal not depressed:

Selector lever is locked and cannot be shifted out of “P” position

when the push-button is pressed. Solenoid for selector lever lock
blocks selector lever.
• Brake pedal is depressed:
Solenoid for selector lever lock releases selector lever. It is pos‐
sible to shift into a driving gear. Slowly shift selector lever from
“P” through to “S”, checking whether selector lever position in
dash panel insert corresponds to selector lever position.
Selector lever in “N” position and ignition switched on
• Brake pedal not depressed:
Selector lever is locked and cannot be shifted out of “N” position
with the push-button pressed. Solenoid for selector lever lock
blocks selector lever.
• Brake pedal is depressed:
Solenoid for selector lever lock releases selector lever. It is pos‐
sible to shift into a driving gear.
Selector lever in Tiptronic position
• Shift selector lever into Tiptronic
gen AG
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kswagen AG
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The illumination ofdthe
by “D” symbol in the selector mechanism
V t gu
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er must go out.or“+”
ise and “-” symbols must light up. nte
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ut or
When the selector
ss
a
lever is shifted into the Tiptronic gate, the se‐
ac
lector lever position display in the dash panel insert must change
ce
le
un
pt
from “P R N D S” to “6 5 4 3 2 1”.
an
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Ignition and light switched on

ab
ility
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The respective symbol in the shift mechanism cover lights up.

wit
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Selector lever position indicator

spec
Simultaneous illumination of all selector lever position display

t to the co
segments indicates gearbox emergency running mode.
3.8 Checking and adjusting selector lever

rrectne
cable
ss

o
cial p
f in

form
mer
atio
om
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Prote AG.
Brief description
Selector lever cable must be removed from gearbox so that its
ease of movement can be checked. Put removed end down so it
does not rub against anything.
Then the selector lever must be moved and after that, the Bowden
cable must be reattached to the gearbox.
Then the selector lever cable must be adjusted.
Do not grease connections of cable!

Always adjust selector lever cable if the following applies:
♦ The selector lever cable has been removed from the gearbox.
♦ The engine and/or gearbox has been removed and installed.
♦ Parts of the assembly mounting have been removed and in‐
stalled.
♦ The cable itself or the selector mechanism has been removed
and installed.
♦ The position of the engine and gearbox is shifted, for example
to install it free of tension.
Check
• Air filter housing is removed. ⇒ Rep. gr. 24 ; Air filter; Re‐
moving and installing air filter housing
– Switch selector lever to “P” position.
– Push ball socket -1- of selector lever cable
n Aoff
G. Vgearbox
olkswagenselector
AG do
lever using removal lever - 80-200- wage
olks .
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– Shift selector lever severalritimes
se
d
from position »P« to »S« and nte
back to »P«. au
tho eo
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• Selector lever must move easily.
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nl
pt
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an
Adjusting
itte
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ab
– Move selector lever in vehicle to “P” position.
ility
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– Selector shaft on gearbox is also in position “P”. To check,

push lever opposite to driving direction to rear stop. h re
hole
spec
es, in part or in w
t to the co
Note
Raise vehicle, to be sure that the gearbox is in “P” (parking lock

rrectness of i
engaged). It should not be possible to turn both front wheels to‐

l purpos
gether in the same direction.

nform
ercia
– Loosen adjustment screw -arrow- for selector lever cable.

m
at
om
– Gently push knob of selector lever forwards and backwards

ion
c
but under no circumstances must you shift out of “P”.

in t
or
his
ate
– Tighten bolt -arrow- to 15 Nm.

do
priv
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or
This completes the adjustment.

f
en
ng
t.
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op
– Install air filter housing ⇒ Rep. gr. 24 ; Air filter; Removing C py
t. rig
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Prote AG.
3.9 Renewing oil seal for selector shaft


♦ Tube - VW 423-
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es, in part or in w
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♦ Extractor hook - T20143- t. Cop py
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Prote AG.
Procedure
• Gearbox is installed.
• Renew bolts that are tightened with turning further angle after
each removal.
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;

Removing and installing battery . gen AG
. Volkswagen AG
a does
lksw n
– Push ball socket -1- of selector
db
lever
yV
o
cable off gearbox selectorot gua
lever using removal leverori- 80-200- .
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te
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ab
ility
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, is n
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spec
es, in part or in w
t to the co
– Unscrew bolt -arrow- and remove gearbox selector lever -1-.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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or
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ate
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– Lever out seal using extractor hook - T20143/1- -arrow-.
co lksw
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cted agen
Prote AG.
– Apply gear oil to circumference and sealing lips of new oil seal.
– Fill space between sealing lip and dust lip -arrow- with sealing
grease ⇒ Electronic Parts Catalogue (ETKA) .

AG. Volkswagen AG d
agen oes
olksw no
d byV Golf 2017t g➤
ua , Golf Variant 2017 ➤
ran
e
7-speed dualhorisclutch gearbox 0GC, Volkswagen R GmbH tee - Edition 02.2018
ut or
a ac
ss
– Drive in seal to stop with tube - VW423- , being careful not to
ce
le
un
cant seal.
pt
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itte
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• Closed side of oil seal -arrow- faces towards outside.
erm
ab
ility
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spec
t to the co
rrectness o
– Place gearbox selector lever -1- on shaft for parking lock and
cial p
f in
tighten bolt -arrow-.
form
mer
– Push selector lever onto gearbox selector lever, and adjust
atio
m
selector lever cable ⇒ page 49 .

o
n
c
i
or
n thi
e
– Install battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;

t
sd
va
Removing and installing battery tray .

i
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pr
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fo
Specified torques
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ng
t.
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Prote AG.
4 Removing and installing gearbox

⇒ “4.1 Specified torques for gearbox”, page 54
⇒ “4.2 Removing gearbox”, page 54
⇒ “4.3 Install gearbox”, page 62
4.1 Specified torques for gearbox

Item Bolt Nm
1, 2, 3 M12x55 80
• With insert tool
T10179 or
T10509:
»65 Nm«
4 M12x65 80
5, 6, 7 M10x50 40
8 M12×70 80
A Dowel sleeves for centring
Component Specified torque

Cable retainer to sump (gear‐ 10 Nm
box cover)
Earth lead to starter bolt 20 Nm
4.2 Removing gearbox

♦ Engine and gearbox jack - VAS 6931-
AG. Volkswagen AG d
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♦ Hose clamps to 25 mm - 3094-

rrectness of i
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om
ion
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ate
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♦ Tensioning strap - T10038-
AG. Volkswagen AG d
agen oes
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ab
ility
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, is n
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hole
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es, in part or in w
t to the co
rrectness of i
l purpos
♦ Release lever - 80 - 200-

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Prote AG.
♦ Insert tool, 18 mm - T10179-
4. Removing and installing gearbox 55

♦ Socket - T10061-
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♦ Counter-hold tool - T10172A-
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♦ Gearbox support - 3282-
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Brief description
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The gearbox is removed downwards together with the bevel box.
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Remove battery, air filter housing and starter. The coolant hoses
must be clamped off. Support engine and gearbox before left
subframe mounting is unbolted.
From below:
Remove subframe together with pendulum support and both sus‐
pension links. The steering rack remains installed in the vehicle.
Both drive shafts are disconnected from gearbox and left installed
in wheel bearing housings. They are only swivelled to one side
and left on vehicle.
Removing
– Raise vehicle. All 4 supports of lifting platform must be at same
height.
Note
So that the propshaft can be turned later in order to loosen it:
– Move selector lever to »N« position.

– Pull breather connection -1- with breather hose off locking

mechanism -arrow- of battery tray -3-.
– Remove engine cover panel ⇒ Rep. gr. 10 ; Engine cover
panel; Removing and installing engine cover panel .
– Remove air filterwage
housing
n AG. Vol⇒
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agen Agr.
G do24 ; Air filter; Removing
es n
and installing
yV
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– Remove
ho
ris battery and battery tray ⇒ Electrical system;
nte
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27
s aut; Battery; Removing and installing battery . ra
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– Lever off selector lever cable -1- from gearbox selector lever
using removal lever - 80 - 200- .
l purpos
– Unscrew bolts -2-, raise and tie cable support bracket -3- to‐
nform
gether with selector lever cable.
mercia
– Do not bend or kink cable.

at
om
ion
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– Remove charge air pipe ⇒ Rep. gr. 21 ; Charge air system;

in t
or
his
Assembly overview - charge air system .

ate
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cum
for
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t.
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Cop py
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Prote AG.
Note
♦ On a warm engine, the cooling system is under high pressure.

♦ Before removing the coolant hoses on the gearbox, cover the
cap -arrow- on the coolant expansion tank with a cloth and
open carefully.
– Lay lint-free cloths on gear oil cooler and gearbox to catch

escaping coolant.
– Clamp off coolant hoses using hose clamps to 25 mm - 3094-

and disconnect hoses from gear oil cooler.
– Seal connecting necks of gear oil cooler using suitable plugs
from engine bung set - VAS 6122- .

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

gearbox - J743- in -direction of arrow-.
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
Removing and installing starter .
It is advisable to remove the »lower« bolt first.
– Unscrew upper and rear engine/gearbox connecting bolt using

insert tool, 18 mm - T10179- .
Unscrew bolt -arrow- using socket - T10061- .

– If there are hose and cable connections in area of engine sup‐
port eyes for support bracket - 10 - 222 A- , remove these now.
– Set up support - 10-222 A- ⇒ Rep. gr. 10 ; Assembly mount‐
ings; Supporting engine in installation position .
– Remove noise insulation ⇒ General AG.body
Volkswrepairs,
agen AG exterior;
Rep. gr. 66 ; Noise insulation; agen
ksw Assembly overview - enoise not in‐
do s
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sulation . ed
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– Remove lower partau
th of front left wheel housing liner ⇒ General eo
ra
body repairs, exterior;
ss Rep. gr. 66 ; Wheel housing liner; Re‐ c
moving and installing front wheel housing liner .
ce
le
un
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– Remove electrical wiring and retainers from sump at front

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

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es, in part or in w
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– Pull connector -1- off oil level and oil temperature sender -
G266- .
– Remove subframe ⇒ Running gear, axles, steering; Rep. gr.
40 ; Subframe; Removing and installing subframe without
steering rack .
– Remove drive shaft heat shield from bevel box ⇒ Running

gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and
installing drive shaft .
Right drive shaft heat shield is secured with 2 nuts -arrows-.
– Detach left and right drive shafts from gearbox ⇒ Running
olkswagen AG
gear, axles, steering; wageRep. gr.
n AG. V 40 ; Drivedoshaft;
es n Removing and
installing drive lks
Voshaft . ot g
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– Secure both drive shafts on suspension strut with tensioning

ot
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belts - T10038- .
, is n
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hole
The surface protection of the shafts must not be damaged.

spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tio
– Unscrew bolts -A- and -B-, and remove bevel box carrier -1-.
n in
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t.
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– Unscrew bolts -arrows- on bevel box, and remove heat shield

-1-.
– Mark position of propshaft with flexible coupling relative to

output shaft of bevel box -arrows-. en AG. V
olkswagen AG
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es, in part or in w
t to the co
– Unbolt propshaft from bevel box -arrows- ⇒ Rep. gr. 39 ;
Propshaft; Removing and installing propshaft .
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
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for
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– To loosen or tighten propshaft, counterhold on rear final drive op
yi Co
using counterhold tool - T10172A- .
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– Push back propshaft at front as far as stop, raise and tie. co Vo
by lksw
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Note
♦ When removing and installing, do not damage seal in the

propshaft flange -arrow-.
♦ Renew propshaft if damaged. ⇒ Rep. gr. 39 ; Propshaft; Re‐
moving and installing propshaft
♦ All parts of propshaft which have been marked relative to each
other must be reinstalled in the same positions.
– Remove bolts -arrows- of assembly mounting for gearbox.
– Then use spindles of support bracket - 10 - 222 A- to lower

engine/gearbox on gearbox side as far as dimension -a-.
Dimension -a- = about 80 mm
– Remove all connecting bolts except one which is in an easily
accessible place between engine and gearbox.
n AG. Volkswagen AG age does
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– An engine/gearbox connecting bolt -arrow- is located next to

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bevel box -A-.

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es, in part or in w
t to the co
rrectness of i
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To remove gearbox 0GC, align gearbox support - 3282- with ad‐

justment plate - 3282/61- . gen AG
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– Move engine and gearbox db
yjack
Vo - VAS 6931- under gearbox
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The gearbox is separated
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– Remove last engine/gearbox connecting bolt.

un
pt
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– Press gearbox off engine while »observing selector lever ca‐
rm
ab
ble«, and lower gearbox.
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Transporting gearbox ⇒ page 67 .
h re
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Secure gearbox to assembly stand ⇒ page 68 .
es, in part or in w
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Install gearbox ⇒ page 62 .
4.3 Install gearbox
rrectness of i
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Note
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Recalibrate the immobiliser after installing a new gearbox.
on in
r
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thi
s
iva
– Renew needle bearing -arrow- in crankshaft ⇒ Rep. gr. 13 ;

do
r
rp
Crankshaft; Renewing needle bearing in crankshaft . cum

fo
en
ng
t.
– Lightly grease journal and splines on gearbox with high-tem‐
yi Co
op
perature grease ⇒ Electronic parts catalogue (ETKA) .
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t. rig
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pyri by
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cted agen
Prote AG.
– If there are no dowel sleeves -A- in the cylinder block for cen‐
tring the engine and gearbox, insert new dowel sleeves.
• Missing dowel sleeves result in misalignment of the axes of
engine and gearbox, leading to destruction of the needle bear‐
ing in the crankshaft.
– Check for proper seating of intermediate plate.
It must be possible to guide the engine and gearbox together by
hand until the engine flange and gearbox flange make contact all
around.
– If necessary, readjust gearbox support until engine and gear‐
box are »aligned with each other«.
– Turn crankshaft slightly if necessary.
Note
Pay attention to selector lever cable when raising gearbox. Guide

cable as soon as possible into cable support bracket.
Do not grease Bowden cable.

– Tighten gearbox to engine.

– Install new bolts -arrows- of assembly mounting for gearbox.

Specified torque: ⇒ page 65 AG. Volkswagen
n AG do
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– Install pendulum support with new bolts. Specified torque: ⇒
t to the co
Rep. gr. 10 ; Assembly mountings; Assembly overview - as‐
sembly mountings .
rrectness of i
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Re‐
moving and installing starter .
l purpos
– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.

40 ; Drive shaft; Removing and installing drive shafts .
nf
ercia
orm
m
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om
n in
or c
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cu
o
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– Install heat shield for right drive shaft -arrows- ⇒ Running

t.
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gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and . Cop py
installing drive shaft heat shield .
t rig
gh ht
pyri by
Vo
co lksw
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cted agen
Prote AG.

– Carefully remove strainer -1- of oil cooler -2- with a screwdriver

and check for contamination.
– Clean strainer if necessary and clip back in place.
– Fit coolant hoses on gear oil cooler.
– Install wire retainer on sump.
– Fit all electrical connectors on gearbox.
– Install battery tray and battery ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery .
– Check coolant level ⇒ Rep. gr. 19 ; Cooling system, coolant;
Draining and filling coolant . AG. Volkswagen AG d
agen oes
olksw not
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– Install lower part of front left wheel housing liner ⇒ General se d b ara
nte
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; Re‐ hori
eo
ut
moving and installing front wheel housing liner . ss a ra
c
ce
le
– Install noise insulation ⇒ General body repairs, exterior; Rep.

un
pt
an
gr. 66 ; Noise insulation; Removing and installing noise insu‐
d
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lation .
erm
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Specified torques
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♦ ⇒ “4.1 Specified torques for gearbox”, page 54
ole,
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t to the co
rrectness o
cial p
f inform
mer
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⇒ “5.1 Assembly overview - assembly mountings”, page 65
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5.1 Assembly overview - assembly mountings

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1 - Engine support
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❑ ⇒ Rep. gr. 10 ; Assem‐
spec
bly mountings; Assem‐
es, in part or in w
bly overview - assembly
t to the co
mountings
2 - Engine mounting
rrectness of i
❑ ⇒ Rep. gr. 10 ; Assem‐
l purpos
bly mountings; Assem‐

bly overview - assembly
mountings
nform
ercia
3, 4, 5 - Bolt
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❑ Specified torque ⇒ Rep.
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gr. 10 ; Assembly
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mountings; Assembly
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overview - assembly
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7, 8, 9 - Bolt
agen
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gr. 10 ; Assembly
mountings; Assembly
overview - assembly
mountings
10 - Pendulum support
11 - Bolt
❑ For pendulum support
to subframe
gr. 10 ; Assembly
mountings; Assembly
overview - assembly
5. Assembly mountings 65
mountings
12 - Bolt
❑ For pendulum support to gearbox
AG. Volkswagen AG d
❑ Gearbox with threaded insert ⇒ page 66 lksw
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not
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❑ Specified torque ⇒ Rep. gr. 10 ; Assembly mountings; eAssembly
d by overview - assembly mountings ara
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13 - Bolt au
th or
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❑ For pendulum support to gearbox
an
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❑ Gearbox with threaded insert ⇒ page 66
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wit
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14 - Bolts
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❑ For gearbox mounting to gearbox
❑ Qty. 3
❑ 60 Nm +90°
rrectness of i
15 - Bolt
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❑ Specified torque ⇒ Rep. gr. 10 ; Assembly mountings; Assembly overview - assembly mountings
nf
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16 - Gearbox mounting
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Gearbox with threaded insert (e.g. “Heli-Coil”) for securing pen‐

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♦ There are threaded inserts, e.g. “Heli-Coil” in the bolting holes Prote AG.
for the pendulum support.
♦ Distinguishing feature: shoulder along beginning of thread
-arrow-.
♦ Note appropriate securing bolts and specified torque ⇒ Rep.
gr. 10 ; Assembly mountings; Assembly overview - assembly
mountings .

6 Transporting gearbox
♦ Gearbox mounting support - 3336-
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♦ Workshop hoist - VAS 6100-
t to the co
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l purpos
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tion in
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Transporting gearbox
n
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Cop py
– Bolt gearbox lifting tackle - 3336- to gearbox. When doing this,
t. rig
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lock in housing recess -arrow-. cop Vo
by lksw
cted agen
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– Adjust support beam on sliding piece using locking pin

-arrow-.
• Number of visible holes (without bevel box) = 5.
• Number of visible holes (with bevel box) = 3.
– With gearbox lifting tackle - 3336- attached, take up weight of
gearbox using workshop hoist - VAS 6100- .
6. Transporting gearbox 67
7 Installing to engine and gearbox sup‐

port
♦ Retainer - VW 309-
♦ or support plate - VW 309 A-
♦ Gearbox support - VW 353- AG. Volkswagen AG d

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♦ Engine and gearbox support - VAS 6095A-
rrectness o
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cted AG.
agen
engine and gearbox support - VAS 6095- with retaining plate
- VW 309- .
Tip:
Risk of oil escaping when gearbox is turned.
♦ If the filled gearbox on the engine and gearbox support is
turned with the breather downwards, the breather on the gear‐
box housing must be sealed.

8 Gear oil circuit

⇒ “8.1 Assembly overview - gear oil circuit”, page 69
⇒ “8.2 Removing and installing gear oil cooler”, page 69
⇒ “8.3 Removing and installing gear oil filter”, page 72
⇒ “8.4 Removing and installing motor for auxiliary hydraulic pump
1 for gearbox oil V475 ”, page 73
8.1 Assembly overview - gear oil circuit
1 - Breather cap
2 - O-ring
❑ Renew
3 - Bolt
❑ 15 Nm + 60°
4 - Gear oil cooler
⇒ page 69
5 - Gearbox
⇒ page 54
6 - Bolt
❑ 8 Nm + 45°
❑ Renew
AG. Volkswagen AG d
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⇒ page 73 ss c
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9 - Gear oil filter

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❑ Information about oil

h re
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and filter change

spec
⇒ page 5
es, in part or in w
t to the co

⇒ page 72
rrectness of i
10 - O-ring
❑ Renew
l purpos
❑ Lubricate with gear oil

nform
ercia
11 - Filter housing
m
❑ 50 Nm
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12 - Heat insulation
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8.2 Removing and installing gear oil cooler

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8. Gear oil circuit 69

♦ Hose clamps to 25 mm - 3094-
Removing agen
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– Move selector lever to position “P”.ed by V gu
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– Remove air filter housing ⇒ Rep. aut gr. 24 ; Air filter; Removing
h eo
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– If necessary, remove battery and battery tray ⇒ Electrical sys‐

an
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tem; Rep. gr. 27 ; Battery; Removing and installing battery

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tray .
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Note
spec
♦ On a warm engine, the cooling system is under high pressure.

t to the co
♦ Before removing the coolant hoses on the gearbox, cover the

cap -arrow- on the coolant expansion tank with a cloth and
rrectne
open carefully.
ss
– Lay lint-free cloths on gear oil cooler and gearbox to catch

o
cial p
escaping coolant.
inform
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7-speed dual
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– Clamp off coolant hoses ed byto gear oil cooler with hose clamps uato
ra
25 mm - 3094- andhoremove.
ris Loosen hose clips -arrows- to dontee
this. au
t or
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ss
– Seal open lines and unions with suitable plugs -1- from engine
ce
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pt
bung set - VAS 6122- .
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Caution
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spec
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– Cover gearbox with cloths to catch any escaping coolant.
rrectne
– Unscrew bolts -arrows- and remove gear oil cooler -A-.
ss o
cial p
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Installing Prote
cted AG.
agen

♦ Renew O-rings -arrows- after each removal.
♦ Coat O-rings with gear oil to prevent pinching of rings during
assembly.
♦ If sealing surface on gear oil cooler is damaged, it must be
renewed.
– Carefully remove strainer -1- of oil cooler with a screwdriver

and check for contamination.
– Clean strainer if necessary and clip back in place.

olkswagen AG
en AG. V
– Carefully bring gearoloil
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ag doesWhen doing
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– If removed, install battery and battery tray ⇒ Electrical system;
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Rep. gr. 27 ; Battery; Assembly overview - battery .
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– Check oil level and top up ⇒ page 77 .
h re
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– Check coolant level ⇒ Rep. gr. 19 ; Cooling system, coolant;
es, in part or in w
Draining and filling coolant .
t to the co
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Assembly overview - noise insula‐
rrectness of i
tion .
l purpos
Specified torques
♦ ⇒ “8.1 Assembly overview - gear oil circuit”, page 69
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8.3 Removing and installing gear oil filter
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Removing
– Remove noise insulation -1- ⇒ General body repairs, exterior;
insulation .
– Remove battery and battery tray -1- -arrows- ⇒ Electrical sys‐
tem; Rep. gr. 27 ; Battery; Removing and installing battery .
– Place used oil collection and extraction unit - VAS 6622A- un‐
der gearbox.
TIP:
♦ A residual amount of gear oil remains in the oil filter. It runs out
when filter housing is unscrewed.
♦ Before unscrewing the filter housing, cover the area around
the gear oil filter with a sufficient number of cloths.
♦ Thoroughly clean oily areas on gearbox.

– Unscrew filter housing -2- and remove filter element.

Renew missing or damaged heat insulation -1-.
Installing
• Renew O-ring after each removal.
– Insert filter element -1- with intake collar -arrow- into gearbox.
– Tighten filter housing.
– Install battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Exploded view - battery .
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– Check oil level
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– Install noise
au insulation ⇒ General body repairs, exterior; Rep. ac
ss
gr. 66 ; Noise insulation; Assembly overview - noise insula‐
ce
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tion .
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8.4 Removing and installing motor for auxil‐

t to the co
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Removing

– Release electrical connector for auxiliary hydraulic pump 1 for

gearbox oil - V475- -a- and pull off connector -b-. AG. Volkswagen n AG do
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Installing
– Renew gasket.
– Push pump motor evenly into housing by hand.
– Tighten pump motor.
– Top up gear oil ⇒ page 80 , and check gear oil level
⇒ page 77 .
Specified torques

9 Gear oil
⇒ “9.1 Overview of oil drain and inspection plugs”, page 75
⇒ “9.2 Tools for gear oil change”, page 75
⇒ “9.3 Checking gear oil level”, page 77
⇒ “9.4 Draining and filling gear oil”, page 80
9.1 Overview of oil drain and inspection plugs
1 - Overflow pipe
❑ 3 Nm
2 - Seal
❑ Renew
3 - Drain plug
❑ For gear oil
❑ 45 Nm
4 - Drain plug for mechatronic
unit
❑ 10 Nm +45°
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9. Gear oil 75
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♦ If necessary: adapter - VAS 6262/6- or adapter - VAS 6262/7-
♦ One-litre bottle of Genuine oil, DSG transmission oil; part

number ⇒ Electronic Parts Catalogue
♦ Vehicle diagnostic tester

♦ Safety glasses
♦ Acid-resistant protective gloves

Measure length of breather pipe attached to adapter for filling oil

- VAS 6262 A- and shorten as necessary.
In order to ensure that the breather pipe of the -VAS 6262 A-
adapter for oil filling does not touch the bottom of some oil bottles,
the pipe must be shortened to the length -a-.
• Dimension -a- = 210 mm.
• The dimension -a- is measured from the shaft (green area in
the magnifying glass) of the adapter for oil filling -VAS 6262
A- .
– Mark dimension on the breather pipe and shorten pipe with

pipe cutter -6056/2- .
– Clean adapter for filling oil - VAS 6262 A- .
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♦ ⇒ “9.2 Tools for gear oil change”, page 75
Procedure
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Test conditions
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• Gearbox not in emergency running mode.
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• Vehicle is placed on a four-pillar lifting platform or above an

assembly pit to ensure it is in total horizontal position.
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• Selector lever in position “P”.
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• The parking brake button has been pulled to activate the elec‐
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• Air conditioning system and heater switched off. Prote AG.
Reading gear oil temperature

♦ The gear oil level changes depending on the gear oil temper‐
ature: if the gear oil temperature is too low, too much gear oil
may be filled; if the gear oil temperature is too high, an insuf‐
ficient amount of gear oil may be filled.
♦ An improper gear oil level impairs the function of the gearbox.
♦ At start of work, the oil temperature must not be above 30°C.
If necessary, allow the gearbox to cool down.
♦ Test temperature: 35 to 45°C.
– Connect vehicle diagnostic tester -arrow- and identify vehicle
in Guided Functions .
9. Gear oil 77
– Select Dual clutch gearbox .

– Select Check oil level .
• Specification at start of test: not higher than 30°C, otherwise
allow the gearbox to cool down.
Checking gear oil level
insulation .
Caution
Risk of injury to eyes and hands from escaping oil.

• Wear protective goggles.
• Wear acid-resistant gloves
– Place used oil collection and extraction unit - VAS 6622A- be‐
low gearbox.
• Engine is running at idling speed with selector lever in “P”.
– Unscrew inspection plug -arrow-.
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• The accumulated gear oil flows out of the overflow pipe

-arrow 2-.
• Irrespective of the gear oil level there is always a slight amount
of gear oil which escapes when the inspection plug -arrow 1-
is opened.
Caution
Gearbox damage from overfilling.

The correct oil level is below the level of the overflow pipe.
For this reason, the overflow pipe must be unscrewed 2 turns
to enable the oil level to be checked and adjusted correctly.
– Loosen overflow pipe 2 turns.

• If some gear oil still escapes at a gear oil temperature of be‐
tween 35 and 45°C (caused by the increasing temperature),
the gear oil level is OK.
• Irrespective of the gear oil level a small gush of oil escapes
from the overflow pipe every 30 seconds due to the cooling oil
pulses for supplying the multi-clutch. This is not relevant for
determining the gear oil level.
• Do not re-use gear oil which has escaped.
– If the gear oil level is OK, tighten the overflow pipe and com‐
plete the work sequence ⇒ page 80 .
Fill with gear oil
Caution
Gearbox damage from overfilling.

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The correct oil level is below the level of the overflow pipe.
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• The overflow pipe must be unscrewed by 2 turns.

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– If no gear oil escapes on the overflow pipe at a gear oil tem‐

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perature of between 35 and 45°C, fill gear oil as follows.

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– Shake bottle before opening.

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– Screw dual clutch gearbox oil bottle onto adapter for oil filling
es, in part or in w
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- VAS 6262 A- , use adapter - VAS 6262/6- .
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9. Gear oil
– Screw adapter for oil filling - VAS 6262 A- into inspection plug
opening hand-tight.
– Hold bottle with adapter for oil filling - VAS 6262 A- as high as
possible over the dual clutch gearbox, and allow the gear oil
to flow into the dual clutch gearbox.
– To check, if the dual clutch gearbox has been filled sufficiently,
disconnect the quick-release coupling on adapter for oil filling
- VAS 6262 A- at regular intervals, and seal the hose with your
finger or a clean plug.
• The accumulated gear oil flows out of the overflow pipe
-arrow 2-.
• Irrespective of the gear oil level there is always a slight amount
of gear oil which escapes.
• If some gear oil still escapes at a gear oil temperature of be‐
tween 35 and 45°C (caused by the increasing temperature),
the gear oil level is OK.
• Irrespective of the gear oil level a small gush of oil escapes
from the overflow pipe every 30 seconds due to the cooling oil
pulses for supplying the multi-clutch. This is not relevant for
determining the gear oil level.
• Do not re-use gear oil which has escaped.
• Check the gear oil temperature on the vehicle diagnostic test‐
er , while filling gear oil. If 45°C are exceeded, stop filling gear
oil, and allow the gearbox to cool down.
– If the gear oil level is OK, perform the required measures for
completing the work sequence ⇒ page 80 .
Concluding measures
• Renew seal -arrow- for inspection plug.
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– Unscrew adapter forksoil
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– Tighten overflow
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– Tighten inspection plug -arrow-.

spec
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– Switch off ignition and separate diagnosis connections.

Specified torques
rrectne
♦ ⇒ “9.1 Overview of oil drain and inspection plugs”, page 75

♦ Assembly overview - noise insulation ⇒ General body repairs,
ss
exterior; Rep. gr. 66 ; Noise insulation; Assembly overview -

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noise insulation .
inform
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9.4 Draining and filling gear oil

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♦ ⇒ “9.2 Tools for gear oil change”, page 75

Test conditions
• Gearbox not in emergency running mode.
assembly pit to ensure it oislksin
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• The uthparking
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• Engine is not running.

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Caution
Risk of injury to eyes and hands from escaping oil.
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• Wear protective goggles.
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• Wear acid-resistant gloves

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low gearbox.
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– Unscrew inspection plug -arrow-.

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• The accumulated gear oil flows out of the overflow pipe.

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– Remove overflow pipe and allow gear oil to drain.
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– Remove oil drain plug -arrow- from mechatronic unit.

– Allow remaining oil to drain out.
Tip
• Wait about 4 minutes until the whole amount of oil has drained.
– Fit a new sealing ring on oil drain plug of mechatronic unit and
tighten.
9. Gear oil 81
Fill with gear oil

– Screw overflow pipe -arrow- in again to stop.
• It should be possible to screw in the overflow pipe with ease.
– Shake bottle before opening.

– Screw dual clutch gearbox oil bottle onto adapter for oil filling
- VAS 6262 A- .
• Use adapter - VAS 6262/6- if necessary.
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opening hand-tight.
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spec
– Hold bottle with adapter for oil filling - VAS 6262 A- as high as
possible over the dual clutch gearbox, and allow 6 l of gear oil
t to the co
to flow into the dual clutch gearbox.
– Start engine and allow to idle.
– Press brake and shift through all selector lever positions “P, rrectne
R, N, D/S” at idling speed, leaving each position engaged for
ss
about 3 seconds.
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– Switch selector lever to “P” position.

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– Do NOT switch off engine.

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– Then, check oil level and top up as necessary ⇒ page 77 .

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Specified torques
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♦ ⇒ “9.1 Overview of oil drain and inspection plugs”, page 75

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♦ Assembly overview - noise insulation ⇒ General body repairs, t. C rig
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exterior; Rep. gr. 66 ; Noise insulation; Assembly overview - yri
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noise insulation .
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1. Currently, no repairs can be made to gears and shafts 83

39 – Final drive - differential

1 Gear oil
⇒ “1.1 Checking gear oil level”, page 84
⇒ “1.2 Draining and filling gear oil”, page 84
1.1 Checking gear oil level

• The bevel box is bolted to side of the gearbox and has its own
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Procedure
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an
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insulation .
– Unscrew nuts -arrows-.
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– Remove heat shield -1-.
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– Unscrew oil filler plug -1-. co Vo
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• Specification: gear oil level to lower edge of filler hole.
AG.
– If necessary, top up gear oil ⇒ page 84 .

– Install heat shield for drive shaft ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40 ; Drive shaft; Removing and installing heat
shield for drive shaft .
Specified torques
♦ Oil filler plug ⇒ Fig. ““Specified torques”“ , page 88
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Assembly overview - noise insulation .
1.2 Draining and filling gear oil

• The gear oil in the bevel box must only be drained in the event
of repairs. The oil is not intended to be changed on a regular
basis.
• Specifications for gear oil ⇒ Electronic Parts Catalogue (ET‐
KA)
84 Rep. gr.39 - Final drive - differential

♦ Adapter - VAS 6262/6- , if necessary
♦ Filling device for all-wheel drive coupling - VAS 6291A-
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1. Gear oil 85
♦ Genuine oil bottle, gear oil; part number ⇒ Electronic parts

catalogue
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Draining
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• Renew oil drain plug and bolt for oil filler hole after each re‐
t to the co
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insulation .
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low gearbox.
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– Unscrew oil drain plug -2-, and drain gear oil.

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– Screw in new oil drain plug -2-.

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Filling
– Route hose of charging device for all-wheel drive coupling -
VAS 6291A- through engine compartment.

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– Screw adapter for oil filling -VAS 6291/3- in to stop.
mer
atio
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– Engage angled piece of charging device for all-wheel drive
o
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c
coupling - VAS 6291A- in adapter -VAS 6291/3- .
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or
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• Do not allow hose to sag.

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– Ensure that valve -arrow- is closed.

– Screw oil container -1- onto charging device for all-wheel drive
coupling - VAS 6291A- .
• In the case of some oil bottles, the adapter -VAS 6262/6- must
be used as well.
– Open valve -arrow-, and hold up oil container as shown in il‐
lustration.
1. Gear oil 87
• The bevel box will now be filled.

• If bevel box has been properly filled, oil will emerge from
adapter for oil filling -VAS 6291/3- .
– If gear oil has emerged from adapter for oil filling - VAS
6291/3- , position oil container so that surplus oil can run back
into it.
– When no more oil flows back, remove filling device for all-
wheel drive coupling - VAS 6291A- .
– Screw in »old« oil drain plug and tighten slightly.
– Start engine, engage gear, and allow gearbox to turn for ap‐
prox. 2 minutes.
– Turn off engine and unscrew plug from oil filler hole.
– Check oil level, if necessary top up gear oil again to lower edge
of filler hole.
– Tighten new oil filler plug.
• Clean bevel box thoroughly to remove any remains of the
emerged oil.
– Install heat shield for drive shaft ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40 ; Drive shaft; Removing and installing heat
shield for drive shaft .
Specified torques agen

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1- Oil filler plug ised b ara
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• Renew after removal aut
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• 15 Nm
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2- Oil drain plug
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• Renew after removal
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• 15 Nm
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spec
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐

tion; Assembly overview - noise insulation . t to the co
rrectness o
cial p
f inform
mer
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2 Oil seals
⇒ “2.1 Overview of fitting locations - seals”, page 89
⇒ “2.2 Renewing left oil seal”, page 89
⇒ “2.3 Renewing right oil seal”, page 92
2.1 Overview of fitting locations - seals
1 - Seal, right
❑ Renewing ⇒ page 92
2 - Seal
❑ For selector shaft
3 - Seal, left
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2.2 Renewing left oil seal

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Special tools and workshop equipment required Cop py
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2. Oil seals 89
♦ Puller - T10055-
♦ Drip tray for workshop hoist - VAS 6208- AG. Volkswagen AG d

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♦ Electric drill, commercially available

rrectness of i
Removing
– Remove left drive shaft ⇒ Running gear, axles, steering; Rep.
l purpos
gr. 40 ; Drive shafts; Removing and installing drive shafts .

nform
ercia
Note
m
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Only drill through sheet metal ring (about 3 mm), otherwise bear‐
or
his
e
ing located behind it might be damaged.

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lkswage es n Golf 2017 ➤ , Golf Variant 2017 ➤
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– Greasessdrill
a bit -3- so that metal chips adhere to it. ra
c
ce
– Seal drive shaft aperture on transmission with a clean cloth e
nl
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-2-.
itte
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– Carefully drill a hole with a drill bit -3- (diameter 2 to 4 mm) into
ility
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outer sheet metal ring -1- of oil seal.
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hole
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es, in part or in w
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– Screw a self-tapping screw, approx. 4 mm in diameter, into

hole drilled in oil seal. Do not screw in sheet metal screw too
nf
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far to avoid damaging bearing behind it.
orm
m
– Place drip tray for workshop hoist - VAS 6208- below gearbox.
atio
om
n in
c
– Pull out oil seal using puller - T10055- and adapter -

or
thi
e
T10055/2- .
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Make sure no metal chips get into gearbox and into opening for
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drive shaft. Vacuum out metal chips first if necessary.

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– Carefully remove cloths and make sure that no metal chips get t. C rig
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into gearbox. yri
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– Carefully clean gearbox and opening for drive shaft.
agen
Prote AG.
If only the sheet metal ring could be pulled out, carefully lever out
rest of seal with a screwdriver.
Installing
Before installing the seal, apply sealing grease for oil seal - G 052
128 A1- to sealing lips and cavity, and apply oil to outer circum‐
ference.
Installation position:
Open side of oil seal faces gearbox.
– Drive oil seal in to stop with thrust piece - T10457- . Do not

cant oil seal in the process.
2. Oil seals 91
– Grease splines -arrow- of stub shaft with universal grease -

G 060 735 A2- .
– Install left drive shaft ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Drive shaft; Removing and installing drive shaft .
– Check oil level and top up ⇒ page 75 .
2.3 Renewing right oil seal

AG. Volkswagen AG d
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♦ Extractor hook - T20143-

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♦ Sealing grease - G 052 128 A1-

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Procedure Cop py
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– Place used oil collection and extraction unit - VAS 6622A-

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– Lever out oil seal on dual clutch gearbox
ris using extractor tool nte
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- T20143/1- or - T20143/2- . sa
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– Moisten new oil seal with gear oil along its outer circumfer‐
l purpos
ence.
nf
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grease - G 052 128 A1- .
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– Carefully drive in oil seal to stop using thrust piece - T10049- . Prote AG.
2. Oil seals 93
3 Differential
⇒ “3.1 Removing and installing right flange shaft”, page 94
3.1 Removing and installing right flange

shaft
AG. Volkswagen AG d
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♦ Puller - T10037-
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♦ Socket - T10107A-
nform
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Removing


– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .
– Place used oil collection and extraction unit - VAS 6622A- be‐ n AG. Volkswagen AG do
low gearbox. wage es n
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– Remove bolt for right flange shaft using socket - T10107 ris A- by
ed nte
screwing 2 bolts into flange and counterholding flange
au
tho shaft eo
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with an assembly lever. ss c
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– Pull out flange shaft -1- using puller - T10037- .
-A- = M10 x 25 bolts
rrectness of i
l purpos
Note
nform
ercia
Use puller - T10037- to remove the flange shaft to avoid damage

to bearings of the flange shaft.
m
a
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tion in
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In the upper area of the bevel box, there is a hexagon bolt -B- with
thi
s
iva
an M 8 stud.
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– To support the puller fit the thrust piece - T10135- onto this
en
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t.
hexagon bolt.
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– Pull out flange shaft. Prote
cted AG.
agen
Installing
– Remove seal -A- from groove -arrow- and renew.

– Carefully drive in flange shaft while turning it.
– Bolt on flange shaft.
– Check gear oil level ⇒ page 84 .
Specified torques
♦ ⇒ “2.1 Assembly overview - bevel box”, page 32
♦ Drive shafts; Assembly overview – drive shafts ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Drive shaft; Assembly
overview – drive shaft
3. Differential 95
4 Components of bevel box

⇒ “4.1 Assembly overview - components of bevel box”,
page 96
⇒ “4.2 Renewing right oil seal”, page 97
⇒ “4.3 Renewing left oil seal”, page 98
⇒ “4.4 Renewing needle bearing for right flange shaft”,
page 100
⇒ “4.5 Removing and installing output flange”, page 101
4.1 Assembly overview - components of bevel box
1 - Seal
❑ Between bevel box and
gearbox
2 - Bevel box
3 - Oil drain plug
❑ With captive seal
❑ Renew after removal AG. Volkswagen AG d
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5 - Seal
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❑ For right flange shaft

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6 - Breather pipe
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❑ To vent bevel box

❑ Press in until stop is
rrectness of i
reached
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7 - Cap
❑ To vent bevel box
nf
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8 - Right flange shaft

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⇒ page 94
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9 - Seal
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❑ Insert in annular groove

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of right flange shaft.

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❑ To renew, remove needle bearings (polygon bearings) -item 10- C py
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10 - Needle bearing (polygon bearing)
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11 - Retaining ring

12 - 12-point nut
❑ Secure new nut by peening ⇒ page 110
❑ 340 Nm
13 - Output flange
14 - Shim
❑ No replacement part
15 - Seal
❑ For bevel box output flange.
16 - Tapered roller bearing inner race
17 - Bolt
❑ 38 Nm
18 - Pinion housing
❑ With shaft bevel gear and tapered roller bearing outer race
❑ Carefully lever out on alternate sides
❑ Observe bolt holes; pinion housing fits in one position only
19 - O-ring
❑ To renew, unscrew bolts g-item
AG.17-,
Volksand carefully
wagen AG do lever off pinion housing at recesses
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❑ Do not remove 12-point
by
Vol nut -item 12- and output oflange
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-item 13-
d ran
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20 - Shim ho
ri tee
aut or
ac
❑ No replacement
ss part
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❑ Observe bevel box bolt holes; shim fits in one position only
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21 - Cap
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4.2 Renewing right oil seal

es, in part or in w
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4. Components of bevel box 97

♦ Sealing grease ⇒ Electronic parts catalogue (ETKA)

Procedure
– Remove right flange shaft ⇒ page 94 .
– Pull out right oil seal using extractor hook -T20143/2- .
– Drive in new oil seal to stop using thrust piece - T10049-

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– Install right flange shaft ⇒ page 94 .orise tee
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– Check gear oil level ⇒ page 84 .ss a ac
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4.3 Renewing left oil seal

rrectness of i

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tion in
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Rep. gr.39 - Final drive - differential Prote AG.
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♦ Sealing grease ⇒ Electronic parts catalogue
ut
hor
(ETKA) eo
a ra
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Procedure s
ce
le
un
pt
– Remove bevel box ⇒ page 33 .
an
d
itte
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ab
– Lever out seal on bevel box using puller hook - T20143/1- or
pe
ility
- T20143/2- .
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hole
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
m
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– Drive in new oil seal to stop using thrust piece - T10298- . Make n AG. Volkswagen AG do
sure to keep seal straight in the process. olks
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– Install bevel box ⇒ page 35 . db ara
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4.4 Renewing needle bearing for right flange shaft
rrectness of i
Special tools and workshop
l purpos
equipment required
nform
mercia
at
om
ion
c
in t
or
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ate
do
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cum
for
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Cop py
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Prote AG.
♦ Thrust plate - VW 401-

♦ Press tool - VW 407-
♦ Assembly tool - VAS 3253-

♦ Tensioning device - T10047-

Procedure
– Remove right flange shaft ⇒ page 94 .
wage es n
– Fit tensioning device - T10047- as
yV
shown
olks in illustration. ot g
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• Markings “B” on both partshofori tool must face towards each
s tee
other aut or
ac
ss
• The shoulders -arrows- must then be below the bearing.
ce
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un
pt
an
d
itte
– Screw parts together up to stop.
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pe
ility
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– Remove retaining ring -A-.
es, in part or in w
t to the co
– Turn shaft -arrow- while pressing off to avoid damage to run‐
ning surface of needle bearings on shaft.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
– Turn shaft -arrow- while pressing on to avoid damage to run‐
fo
en
g
ning surface of needle bearings on shaft.

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– Secure needle bearings with a new retaining ring.
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– Install right flange shaft ⇒ page 94 .
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4.5 Removing and installing output flange

Special tools and workshop wage

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equipment required yV
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♦ Thrust piece - VW 454-
♦ Installing sleeve - VW 455-

AG. Volkswagen AG d
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c
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♦ Support rails - VW 457-
AG.
♦ Tube - 3296-
♦ Gearbox support - T10108- with stop plate - T10108/1-
♦ Tapered roller bearing puller - V.A.G 1582-
♦ Grip tool - V.A.G 1582/13-
♦ Crankshaft seal installing tool - VW 204 B-

♦ Universal dial gauge holder - VW 387-
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♦ Thrust plate - 40 - 105-
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
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com
tion in
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iva
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♦ Socket, 34 mm - T50019-
rp
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♦ Dial gauge - VAS 6080-
♦ Sealing grease ⇒ Electronic parts catalogue (ETKA)

♦ Bolt M10x30 (qty. 2)
♦ Bolt M8x25 (qty. 1)
♦ Nut M12x10 (qty. 4)

Procedure
♦ There is a tapered roller bearing inner race pressed onto bevel
box output flange.
♦ This is removed later in the process.
♦ The tapered roller bearing for the bevel box output flange and
the shims are not to be renewed.
– Remove bevel box ⇒ page 33 .
– Set bevel box on hole “arrow” in gearbox support - T10108-
marked with number -4-. To do so, place an M12x10 nut
-item A- between bevel box and gearbox support.
– Then, align bevel box with remaining 3 holes, and secure it
with nut -A- placed between bevel box and gearbox support.
– Drain oil from bevel box ⇒ page 84 .
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un
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itte
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– Release peened points -arrows- of 12-point nut -A- from in‐
pe
ility
dentations of output flange -B- by driving them inwards.
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
– Lock bevel box output flange with stop plate - T10108/1- by

com
tion in
screwing in two M10 x 30 bolts -arrows-.

r
te o
thi
A - Socket, 34 mm - T50019-
s
iva
do
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rp
cum
– Remove output flange nut.

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– Swing bevel box so that output flange points upwards.
ss c
ce
le
un
pt
– Unscrew bolts -arrows- for pinion housing -A-.
an
d
itte
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rm
ab
pe
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Fit a suitable flat-bladed screwdriver -B- into the three recess‐

es -arrows- of pinion housing -A- and carefully lever off pinion
nform
ercia
housing together with shaft bevel gear.

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tion in
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Prote AG.
– Position output flange -A- evenly on support rails - VW 457-

-arrows-.
– Press shaft bevel gear off output flange -A-.
• Secure shaft bevel gear and tapered roller bearing inner race
from falling down.
– Press output flange -A- out of pinion housing.

Seal -arrow- is located on output flange.
• Tapered roller bearing inner race must be removed in order to

remove output flange seal.
Caution
Risk of damage to tapered roller bearing inner race.

• Pull off tapered roller bearing inner race using adapter
n AG-. Volkswagen AG do
V.A.G 1582/13- . lkswage es n
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• If tapered roller bearing inner race is hdamaged,
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bevel box tee
must be renewed. ut o or
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un
pt
an
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– Place thrust plate - 40 - 105- on output flange.

itte
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ab
– Using tapered roller bearing puller , pull tapered roller bearing
pe
ility
ot
inner race off output flange.
wit
, is n
h re
– Remove seal from output shaft.
hole
spec
es, in part or in w
t to the co
– Insert old tapered roller bearing inner race -1- into pinion hous‐
ing.
– Lightly oil outer circumference of new seal -2- for output flange.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
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– Press in oil seal flush.

t.
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• Make sure that larger diameter of -VW 204 B- faces oil seal.
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– Fill half of space between sealing lip and dust lip with sealing
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Prote
grease; sealing grease ⇒ Electronic parts catalogue .
AG.

– Press tapered roller bearing inner race ⇒ page 107 onto output
flange as far as it will go.
• Make sure that larger diameter of press tool -VW 454- faces
output flange.
• Press on tapered roller bearing inner race as far as stop. Do
not expose the tapered roller bearing to higher forces than
necessary.
– Fit shim -2-, tapered roller bearing inner race -3- and pinion
housing -4- onto shaft bevel gear -1-.
• Reinstall old shim -2-. It assures bearing preload of shaft bevel
gear in pinion housing.
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– Tighten bolts -arrows- for pinion housing -A- diagonally and

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– Tighten new 12-point nut for output flange.

A - Socket, 34 mm - T50019-

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– in indentations (offset by 120°) of output flange -B- by peening
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Service

Service Department. Technical Information

39 - Final drive - differential

All rights reserved.

Copyright © 2018 Volkswagen AG, Wolfsburg D4B807111A7

30 - Clutch . . . . . . . . . . . . . . . a.g.en.A.G.. V.o.lks.w.ag. e.n .AG. d.o. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1.4 Installing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.1 Assembly overview - mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1.2 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1.3 Removing and installing mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.2 Removing bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

2.3 Installing bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.1 Assembly overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3.2 Emergency release from position P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3.3 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

3.4 Moving push-button in the handle to installation position . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3.5 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

3.6 Removing and installing gear selector cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

4 Components of bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

4.1 Assembly overview - components of bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

4.2 Renewing right oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

4.3 Renewing left oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

4.4 Renewing needle bearing for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

⇒ “1.4 Safety precautions when using testers and measuring in‐

1.1 General safety provisions

observe the following:

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

To prevent damage to the electronic components when dis‐

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

1.2 Safety measures when working on ve‐

Injury hazard as a result of automatic engine start in vehicles

Danger of irreparable damage to gearbox.

1.4 Safety precautions when using testers

and measuring instruments during a

Risk of accident due to distraction and inadequate securing of

2 Rep. gr.00 - Technical data

To prevent damage to the electronic components when dis‐

2.1 Gearbox identification

The gearbox codes can be found on top of the gearbox.

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

4 Rep. gr.00 - Technical data

3.1 General information

♦ First thoroughly clean connecting points and surrounding

areas and then loosen bolts.

♦ Seal open lines and connections immediately using clean

plugs or sealing caps from engine bung set - VAS 6122- .

♦ Place removed parts on a clean surface and cover them to

♦ Install only clean parts; do not remove Genuine parts from

packaging until immediately before installing.

♦ Protect disconnected electrical connectors from dirt and water,

and reconnect them only when dry.

3.3 General repair instructions

To ensure flawless and successful gearbox repairs, the greatest

A number of general notes on the individual repair procedures,

♦ Retaining rings must locate properly in grooves.

3.4 Gaskets and seals

♦ Renew O-rings, seals and gaskets.

♦ After removing gaskets and seals, always inspect contact sur‐

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