Service
Service
Service
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Workshop Manual
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ ,
rrectness of i
Golf 2009 ➤ , Golf Plus 2005 ➤ ,
l purpos
nform
ercia
at
om
ion
c
in t
or
satelettronica
his
e
do
priv
cum
for
en
g
Edition 01.2018
n
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Repair Group
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - differential
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
satelettronica
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
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.
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4 Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 DSG® oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.6 Oil filter change - »Yes or no?« . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.7 Oil drain and inspection plug A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.8 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.9 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Fault findinggen. A.G. ..V.ol.ks. w. a.g.en. A. G. d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
a oes
2.1 General ksw
Vol notes on fault finding . . . .ot. g.u. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
n
by aa
2.2 Useful
ris
ed information about the “behaviour rof ntthe
e
control unit in the event of a gearbox fault”
ut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . e. o.r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ho
5
a a
2.3ss Special notes on fault finding . . . . . . . . . . . . .c. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
satelettronica
ce
e
nl
3 Identification of gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
pt
du
an
itte
ab
4 ility
Code - engine allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ot p
4.1 wit
Golf Plus 2009 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
, is n
h re
4.2 Golf Plus 2005 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
hole
spec
t to the co
5 Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
atio
om
n in
or c
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
thi
te
sd
iva
1 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
o
r
rp
cu
o
en
ng
t.
yi
1.2 Removing and installing clutch end cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Co
Cop py
t.
1.3 Removing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
rig
gh ht
pyri by
1.4 Installing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
co Vo
by lksw
cted agen
Prote AG.
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1 Electrical and electronic components and their locations DSG® . . . . . . . . . . . . . . . . . . . . 31
1.1 Removing and installing mechatronic unit for dual clutch gearbox J743 (gearbox installed)
........................................................................ 31
1.2 Removing and installing mechatronic unit for dual clutch gearbox J743 (gearbox removed)
........................................................................ 40
1.3 Removing and installing gearbox input speed sender G182 and oil temperature sender in
multi-plate clutch G509 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2 Removing and installing gear oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4 Renewing selector shaft lever oil seal with gearbox removed . . . . . . . . . . . . . . . . . . . . . . 55
5 Emergency release of selector lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6.1 Moving push-button in the handle to installation position . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Contents i
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus A2005
G. Volk➤
swa...
gen AG
agen does
6-speed dual clutch gearbox 02E - Edition 01.2018 Volksw not
y gu
db ara
rise nte
o e
7 Selector mechanism up to 02.2009 . . . . . a.ut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .or a 62
h
s c
7.1 Overview of selector mechanism up to 02.2009
s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
ce
le
un
7.2 Removing and installing selector lever cable up to 02.2009 . . . . . . . . . . . . . . . . . . . . . . . . 63
pt
an
d
itte
7.3 Checking selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
y li
rm
ab
7.4 Adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
pe
ility
ot
wit
8 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
, is n
h re
8.1 Selector lever in “P” position and ignition switched on . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
hole
spec
8.2 Selector lever in “N” position and ignition switched on . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
es, in part or in w
t to the co
8.3 Selector lever in position “Tiptronic” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.4 Ignition and light switched on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.5 Selector lever position indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
rrectness of i
9 Selector mechanism from 03.2009 onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
l purpos 73
9.1 Overview of selector mechanism in vehicles from 03.2009 onwards . . . . . . . . . . . . . . . . . . 73
9.2 Removing and installing selector mechanism, from 03.2009 . . . . . . . . . . . . . . . . . . . . . . . . 74
nform
ercia
a
10.1 Removing gearbox, Passat CC 2009 ►, CC 2010 ► with 2.0 l petrol engine . . . . . . . . . . . . 78
com
tion in
10.2 Removing gearbox, Golf 2009 ►, Golf Plus 2009 ► with 2.0 l petrol engine . . . . . . . . . . . . 85
r
te o
thi
10.3 Removing gearbox, Golf Plus 2005 ► with 1.4 l petrol engine . . . . . . . . . . . . . . . . . . . . . . 94
s
iva
do
satelettronica
10.4 Removing gearbox, Passat CC 2009 ►, CC 2010 ► diesel engine . . . . . . . . . . . . . . . . . . 101
r
rp
cum
fo
10.5 Removing gearbox, Passat CC 2009 ►, CC 2010 ► with diesel engine, all-wheel drive . . 111
en
ng
t.
yi Co
10.6 Removing gearbox, Golf Plus 2009 ► with 2.0 l diesel engine . . . . . . . . . . . . . . . . . . . . . . 120
Cop py
t. rig
10.7 Removing gearbox, Golf 2009 ► 2.0 l diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
gh ht
pyri by
Vo
o
10.8 Removing gearbox, Passat CC 2009 ►, CC 2010 ► with 3.6 l - V6 engine (all-wheel drive) by c lksw
cted agen
........................................................................ 135
Prote AG.
10.9 Removing gearbox, Golf 2004 ▸ with 1.9 l and 2.0 l diesel engine . . . . . . . . . . . . . . . . . . 142
10.10 Removing gearbox, Golf 2004 ► with 125 kW - 2.0 l diesel engine . . . . . . . . . . . . . . . . . . 149
10.11 Removing gearbox, Eos 2006 ►, with 3.2 and 3.6 l - V6 engine . . . . . . . . . . . . . . . . . . . . 155
10.12 Removing gearbox, Golf 2004 ► with 1.4 l petrol engine . . . . . . . . . . . . . . . . . . . . . . . . . . 162
10.13 Removing gearbox, Golf 2004 ► with 2.0 l petrol engine . . . . . . . . . . . . . . . . . . . . . . . . . . 169
10.14 Removing gearbox, Golf 2004 ►, with 3.2 l - V6 engine (R32 all-wheel drive) . . . . . . . . . . 174
10.15 Removing gearbox, Golf Plus 2005 ► with 1.9 l and 2.0 l diesel engine, with 2.0 l petrol engine
...................................................................... 183
10.16 Removing gearbox, Eos 2006 ► with 2.0 l petrol engine . . . . . . . . . . . . . . . . . . . . . . . . . . 190
10.17 Removing gearbox, Eos 2005 ► with 2.0 l diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . 197
10.18 Removing gearbox, Touran 2003 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
10.19 Removing gearbox, Passat 2006 ► with 2.0 l diesel engine . . . . . . . . . . . . . . . . . . . . . . . . 212
10.20 Removing gearbox, Passat 2006 ► with 2.0 l petrol engine . . . . . . . . . . . . . . . . . . . . . . . . 220
10.21 Removing gearbox, Passat 2006 ► with 3.6 l - V6 engine (all-wheel drive) . . . . . . . . . . . . 225
10.22 Removing gearbox, Scirocco 2009 ► with 2.0 l diesel engine . . . . . . . . . . . . . . . . . . . . . . 231
10.23 Removing gearbox, Scirocco 2009 ► with 2.0 l petrol engine . . . . . . . . . . . . . . . . . . . . . . 240
10.24 Removing gearbox, Sharan 2011 ► with 2.0 l diesel engine . . . . . . . . . . . . . . . . . . . . . . . . 249
10.25 Removing gearbox, Sharan 2011 ► with 1.8 l and 2.0 l petrol engine . . . . . . . . . . . . . . . . 257
10.26 Removing gearbox, Sharan 2011 ► with 1.4 l petrol engine . . . . . . . . . . . . . . . . . . . . . . . . 266
10.27 Install gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
11 Torque settings »gearbox to engine« . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
11.1 Torque settings (ELSA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
12 Transporting gearbox and securing to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
13 Removing and installing bevel box, Golf 2004 ► and Passat 2006 ► . . . . . . . . . . . . . . . . . . 284
14 Removing and installing bevel box, Passat CC 2009 ►, CC 2010 ► with diesel engine . . 289
14.1 Specified torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
15 Removing and installing bevel box, Passat CC 2009 ►, CC 2010 ► with 3.6 l V6 engine . . 297
16 Oil and oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
16.1 Oil filter: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
16.2 Checking oil level and topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
ii Contents
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
6-speed dual clutch gearbox 02E - Edition 01.2018
satelettronica
5 Checking and topping up gear oil in bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
5.1 Checking gear oil in bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
5.2 Topping up gear oil in bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Contents iii
olkswagen AG
en AG. V
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤olk, sGolf
wag 2009 ➤ , Golf Plus
doe2005
s no ➤ ...
V t gu
6-speed dual clutch gearbox 02E -eEdition
d by 01.2018 ara
ris nte
utho eo
ra
a c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
satelettronica
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
iv Contents
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
olkswagen AG
en AG. V dual
ag6-speed clutchdoegearbox 02E - Edition 01.2018
ksw ol sn ot g
yV ua
edb ran
ris tee
00 – Technical data
ss
au
tho or
ac
ce
le
un
pt
an
d
1 General repair instructions
itte
y li
rm
ab
pe
ility
(VRL011359; Edition 01.2018)
ot
wit
1.1 Tools , is n
h re
hole
spec
es, in part or in w
t to the co
the workshop manual precedes each repair procedure and can
be found in “Special tools/Workshop equipment” binder.
The catalogue is also available on ⇒ CD-ROM and can be ordered
rrectness of i
the usual way from Bertelsmann.
l purpos
nform
ercia
bolts.
m
a
com
tion in
r
te o
thi
s
iva
satelettronica
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1.2 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.
♦ Place removed parts on a clean surface and cover them to
prevent them from getting dirty. Use sheeting and paper for
this purpose. Use lint-free cloths only.
♦ Install only clean parts; do not remove Genuine parts from
packaging until immediately before installing.
♦ If repair work cannot be performed immediately, carefully cov‐
er or seal components.
1.3 Overview
ce
le
un
pt
⇒ page 31
an
d
itte
y li
rm
ab
pe
ility
er - G182- and oil temperature
satelettronica
ot
wit
sender in multi-plate clutch -
, is n
h re
G509- ⇒ page 31
hole
spec
7 - Oil pump ⇒ page 51
es, in part or in w
t to the co
8 - Cover (end cover) for dual
clutch
rrectness of i
9 - Dual clutch ⇒ page 16
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
1.4 Seals
t.
yi Co
Cop py
t. rig
gh ht
♦ After removing gaskets and seals, always inspect contact sur‐ yri
p by
o Vo
face of housing or shaft for burrs resulting from removal or for by c lksw
cted agen
other signs of damage.
Prote AG.
ce
le
Do not mix additives in oil. Do not fill any other oil.
un
pt
an
d
itte
y li
Oil which has been drained out cannot be filled again.
erm
ab
ility
ot p
wit
is n
Caution
h re
ole,
spec
Be careful when working with oil. Dispose of drained oil ac‐ urposes, in part or in wh
cording to regulations. Remember: one drop of oil will contam‐
t to the co
inate 600 litres of water.
rrectne
1.6 Oil filter change - »Yes or no?«
satelettronica
ss o
cial p
f
The oil filter does not have to be changed as a matter of course.
inform
mer
atio
om
♦ The gear oil cooler or its O-rings have been renewed and no
n
c
i
or
n
coolant has got into the oil.
thi
te
sd
va
♦ The oil seal for the selector shaft has been renewed.
i
o
pr
cum
r
fo
en
ng
♦ The oil seal for the flange or stub shaft has been renewed.
t.
yi Co
op py
♦ Leaking covers in the mechatronic unit, dual clutch or oil pump
t. C rig
gh ht
yri
have been renewed. p by
o Vo
by c lksw
cted agen
♦ The gearbox input speed sender - G182- with oil temperature Prote AG.
sender in multi-plate clutch - G509- has been renewed.
The filter must be changed if:
♦ The 60,000 kilometre service interval has been reached.
♦ Coolant has got into the oil.
♦ Metal particles have been found in the oil.
♦ The clutch is burnt out or has a mechanical defect.
satelettronica
. Volkswagen AG
a gen AG d
– Before working on electrical components,
Vol
ksw electrostatically dis‐ es not
o
gu
charge yourself (touch something d that is earthed). Do not
by ara
se nte
directly touch connector contacts
thori or electronic components. eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
2.1 General notes on fault finding
ab
ility
ot p
wit
Before making repairs, determine the cause of the fault with the
, is n
h re
aid of “guided fault finding”.
hole
spec
Initiate Guided fault finding using the vehicle diagnosis,
es, in part or in w
t to the co
testing and information system - VAS 5051- .
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
satelettronica
r
rp
cu
o
m
f
en
ng
t.
yi Co
of the control unit in the event of a gear‐ Cop py
t. rig
gh
box fault”
ht
pyri by
Vo
co lksw
by
cted agen
The control unit works with highly developed software. This soft‐
Prote AG.
2. Fault finding 5
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
6-speed dual clutch gearbox 02E - Edition 01.2018
ce
le
un
pt
an
d
y li
erm
ab
Simultaneous illumination of all selector lever position display
ility
ot p
wit
is n
h re
satelettronica
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
of mistakes.
pt
an
d
itte
y li
Only after such faults have been excluded can one work mean‐
rm
satelettronica
ab
pe
ility
ot
wit
, is n
h re
hole
spec
First consider what the saved faults indicate. The VW testers offer
es, in part or in w
t to the co
ing will locate the sources of many faults.
rrectness of i
For example, if the fault “ABS signal missing” is saved in the
l purpos
nform
ercia
The entry means only that the gearbox (and possibly other control
m
a
com
t
units) are expecting a signal via the bus, but does not receive it.
ion in
In this case, it is more likely that the ⇒ ABS control unit has a
r
te o
thi
problem. In such a case, under no circumstances should the me‐
s
iva
do
chatronic unit for dual clutch gearbox - J743- be removed without
r
rp
cum
further consideration. The fault in this example indicates problems
fo
en
g
in the ⇒ ABS.
n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Fault finding 7
. Volkswagen AG
gen AG doe
swa
CC 2010 ➤y ,V Eos 2006 ➤ , Golf 2004 ➤ s,nGolf
olk ot g 2009 ➤
ua
, Golf Plus 2005 ➤ ...
b
6-speed ris dual clutch gearbox 02E - Edition 01.2018
ed ran
tee
tho
u or
a ac
ss
3 Identification of gearbox
ce
e
nl
pt
du
an
itte
y li
Example -arrow-:
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
10.05.2 - 10 May 2002
es, in part or in w
t to the co
14 - Factory code
14 15 - Time
rrectness of i
001 - Serial number
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
satelettronica
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
To see the code directly on the gearbox behind the bracket, the
engine and gearbox must be supported. Bracket -A- for the left-
hand assembly mounting must be removed. In the process, it is
important to lower the engine and gearbox only enough so that
the bracket can be pushed back. If it is lowered further, the ⇒
pendulum support will be damaged. Following assembly, the se‐
lector lever cable must be adjusted ⇒ page 70 .
A detailed description of bracket removal will not be provided in
satelettronica
this chapter. Please refer to the respective chapter “Removing
and installing gearbox” for information on removing the bracket.
Brief description
Remove air filter and battery.
AG. Volkswagen AG d
agen oes
Set up support bracket - 10 - 222 A- and support engine withVolksw not
gu
gearbox. Do not raise. se
db
y ara
nte
ri
ho eo
aut ra
– Remove all bolts -1- and -2- for bracket -A-. ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
⇒ page 70 .
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Identification of gearbox 9
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
6-speed dual clutch gearbox 02E - Edition 01.2018
satelettronica
Dual clutch gearbox (⇒ DSG®) 02E »front-wheel drive«
»LQV«, HJP, JPK, LQT LQZ MDJ
KQC, KPT,
LTE, MFL, HQM,
MSV KMY, LQV,
KQC,
LQW, AG. Volkswagen AG d
agen oes
ksw
LTG, HXT, byV
ol not
gu
ara
HFQ, KCV, rised
nte
MFL, MSV, ut
ho eo
ra
NJK, NLP, ss a c
PBF, PBY
ce
e
nl
pt
du
an
2.0 l - 81 2.0 l - 100, 2.0 l - 125 2.0 l - 147 2.0 l - 155
itte
y li
kW TDI 103 kW kW TDI kW TDI kW TDI
erm
ab
ility
TDI
ot p
wit
, is n
h re
Dual clutch gearbox (⇒ DSG®) 02E »front-wheel drive«
hole
spec
KNF, JPL, LQS,
es, in part or in w
t to the co
KDC, JBT, KPQ,
JPS, HQN,
KMZ,
KCW, HXU
rrectness of i
petrol tur‐
or
bo
m
m
atio
om
thi
te
sd
a
o
r
rp
cu
gearbox code.
o
m
f
en
ng
t.
yi Co
Dual clutch gearbox (⇒ DSG®) 02E . Cop py
rig
ht
»HQN« »HQH« »HJP« »HQM« HVV, JPT, JPS,
rig ht
py by
o Vo
»GPW«, HXU, JPL, »HQG«, »HQG«, KDC, KNF, JBT by c lksw
cted agen
KCW, KMZ, LQS, HXT, HBP, HXU, Prote AG.
satelettronica
If Genuine parts are required for a repair, always refer to the
gearbox code.
Dual clutch gearbox (⇒ DSG®) 02E »front-wheel drive«
PQK, PDY KMX, LQT, LTD, LPY, LQZ, KNC,
KQC, LQV, MFM, MMD, KPV, LTL,
KMX, MSU, n NJJ,
AG. VolkswMTC,
agen AG MMA, MSY,
KCU, MFL, wage d s
Volks NLN NJP, NLT oeNJL,not NLR
LTE, MSV,ed
by gu
ara
NJK,
tho ris NLP nte
eo
u r
2.0 l - 130 ss2.0
a
l -100 ⇒ 2.0 l - 125 2.0 l - 188 2.0 l - 147 ac
kW TDI or 103 kW kW TDI kW, and 155 kW
ce
le
un
pt
FSI turbo
y li
rm
ab
pe
ility
wit
, is n
h re
spec
gearbox code.
es, in part or in w
t to the co
throug GPW ,
h 20 »HB
nform
Sep‐ P,
ercia
tem‐ HLE,
m
ber «
com
tio
2004 HFQ
n in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
DI TDI
nl
pt
du
an
satelettronica
itte
y li
erm
ab
led in ual
ility
ot p
wit
, is n
h re
gearbox code.
hole
spec
es, in part or in w
t to the co
»HUV«, GUF,
GYB, HDD,
rrectness of i
HKA, HPZ,
HXZ, JUQ,
l purpos
KDE, JUQ,
KNL, JPZ,
KQA, JYX,
nform
ercia
KQA, LRF,
m
LTU
at
om
ion
3.2 l - 184 kW
c
in t
or
his
ate
cum
for
en
g
t.
yi Co
gearbox code. Cop py
t. rig
gh ht
yri by
Dual clutch gearbox (⇒ DSG®) 02E
op Vo
by c lksw
cted agen
Prote
HZH, PSN HZH, GPV, MSV, GPQ, HTB, PDY,
AG.
ce
le
un
pt
1.4 l - 1.4 l - 1.4 l - 1.9 l - 2.0 l - 2.0 l - 2.0 l - 2.0 l -
an
d
itte
103 k 110 125 k 77 kW 81 kW 103 k 125 k 130 k
y li
erm
ab
W FSI kW W TSI TDI TDI W TDI W TDI W TDI
ility
ot p
turbo Eco-
wit
is n
Fuel
h re
ole,
spec
4.7 Passat 2006 ►
urposes, in part or in wh
t to the co
If Genuine parts are required for a repair, always refer to the
gearbox code.
rrectne
Dual clutch gearbox (⇒ DSG®) 02E »front-wheel drive«
JPJ HQL, HFQ, HYC, HYC, »LQY«, HBR,
ss o
HXS GSS, HTB, HTB, LTK, HXX
cial p
f in
HQF, JPQ, JPQ, MLZ
form
mer
atio
HXS, KPS, KMW,
om
n
c
i
or
n
KCU, LQT,
thi
te
sd
a
KMX, LTD
iv
o
r
KQC,
p
cum
r
fo
satelettronica
LTE,
en
ng
t.
yi
LTF,
Co
op py
LQV
t. C rig
gh ht
pyri by
2.0 l - 2.0 l - 2.0 l - 2.0 l - 2.0 l - 2.0 l - 3.2 l -
co Vo
by lksw
cted
88 kW 90 kW 100, 120 kW 125 kW 125, 184 kW
agen
Prote AG.
TDI TDI 103, TDI TDI 147 kW FSI
105 kW FSI tur‐
TDI bo
If Genuine parts are required for a repair, always refer to the
gearbox code.
Dual clutch gearbox (⇒ DSG®) 02E »all-wheel drive«
»HXX«, JQZ, MKM,
HBR, KJL, MMH
JPY, KNM,
JVY, LHS,
JYW, LHQ,
KDF, KQB,
KPZ, LRH,
KNK, LTW
LRE,
LTT
3.2 l - 3.6 l - 2.0 l -
184 kW 220 kW 125 kW
FSI FSI TDI
ce
e
nl
pt
du
an
MFL, MSU, MSX, NLQ
itte
y li
erm
ab
ility
NLP NLN NLQ,
ot p
wit
NNU
, is n
h re
2.0 l - 2.0 l - 2.0 l - 2.0 l - 2.0 l -
hole
spec
100 k 103, 125 k 147 k 155 k
es, in part or in w
t to the co
satelettronica
W TDI turbo turbo
rrectness of i
KSA, MKM,
l purpos
KSB, MMH,
LHT, MTZ,
nform
ercia
LHR, NJD
LRJ,
m
at
LTX,
om
ion
MTW,
c
in t
or
NHZ
his
ate
do
riv
3.6 l - 2.0 l -
p
cum
or
220 kW 125 kW
f
en
ng
t.
petrol diesel op
yi Co
engine engine
C py
t. rig
gh ht
pyri by
Vo
4.10 Sharan 2011 ►
co lksw
by
cted agen
Prote AG.
5 Capacity
Capacity Dual clutch gearbox 02E
Initial filling in factory 6.9 l –7.2 l
depending on vehicle and date of
gearbox construction
Change quantity approx. 5.2 litres
Change quantity only me‐ 3 – 4 litres
chatronic unit removal and
installation (gearbox instal‐
led)
Lubricant: ⇒ DSG® oil
Further information in the part number designates the container
size.
The oil is available as a genuine part in ⇒ Electronics parts cata‐
logue “ETKA” .
Capacity Front bevel box
satelettronica
Initial filling 0.9 l
Changing Filled for life, no change
Lubricant Gear oil - G 052 145-
Further information in the part number designates the container
size.
The oil is available as a genuine part in ⇒ Electronics parts cata‐
logue “ETKA” .
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5. Capacity 15
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
6-speed dual clutch gearbox 02E - Edition 01.2018
30 – Clutch
1 Clutch
⇒ “1.1 Assembly overview - dual clutch”, page 16
⇒ “1.2 Removing and installing clutch end cover”, page 18
⇒ “1.3 Removing dual clutch”, page 24
⇒ “1.4 Installing dual clutch”, page 25
satelettronica
If parts are rotated relative to each other during assembly, im‐
balances develop which are detrimental to ease of shifting and
service life.
Replacement parts
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
le
un
pt
3 - Clutch end cover
an
d
itte
y li
rm
ab
4 - Retaining ring for clutch end
pe
ility
cover
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
satelettronica
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Caution
1. Clutch 17
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
6-speed dual clutch gearbox 02E - Edition 01.2018
Caution
Under no circumstances
raise or remove the inner
plate carrier. The plates
could turn.
4 - Outer plates
❑ Qty. 4
5 - Inner plates
❑ Qty. 4
satelettronica
6 - Thrust washer AG. Volkswagen AG d
agen oes
olksw not
V gu
7 - Retaining ring d by ara
ise nte
or
❑ If retaining ring was re‐ aut
h eo
ra
moved to insert new ss c
plates, it should be re‐
ce
e
nl
pt
du
an
itte
y li
equally thick ring.
erm
ab
ility
ot p
8 - Retaining ring
wit
, is n
❑ Determine thickness
h re
hole
spec
been fitted ⇒ page 28
es, in part or in w
t to the co
9 - Drive plate
10 - Retaining ring
rrectness of i
l purpos
er
orm
m
atio
n in
or c
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Brief description
Cover seals off gearbox from atmosphere. Cover is held in its seat
by a retaining ring. After the retaining ring has been removed, the
cover can be levered out of its seat. Cover and retaining ring must
always be renewed. Never install a new cover with a hammer and
never oil the centre seal or touch it with a hand! However, if this
should happen, the cover is certain to leak!
To remove or install cover, gearbox must be securely attached to
an assembly stand in vertical position.
Removing
– Drain gear oil
– Remove gearbox.
– Secure gearbox to assembly stand.
satelettronica
decision.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
ho e
– Insert newafilter with shoulder downwards and tighten coverorto
ut
ac
20 Nm. ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Clutch 19
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
6-speed dual clutch gearbox 02E - Edition 01.2018
– Lever out retaining ring -2- of clutch end cover using screw‐
driver -1- -arrow- and remove.
satelettronica
– Lever clutch end cover -2- out through opening for starter mo‐
tor using screwdriver -1- or tyre lever -arrow- and remove n AG. Volkswagen AG do
swage es n
clutch end cover. by
Volk ot g
ua
ed ran
ris tee
tho or
au ac
Note ss
ce
le
un
pt
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
20
Prote AG.
Rep. gr.30 - Clutch
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
6-speed dual clutch gearbox 02E - Edition 01.2018
Installing
Caution
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
– Only handle cover as shown -inss this picture-.
a ac
ce
le
un
pt
an
d
itte
y li
Note
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
satelettronica
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Clutch 21
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
6-speed dual clutch gearbox 02E - Edition 01.2018
Caution
AG. Volkswagen AG d
agen
satelettronica
oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
– Install clutch end cover with bush.
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
o
Installing covers supplied without bush
rm
m
atio
m
n in
c
a scratched sleeve.
or
thi
te
sd
iva
cu
o
m
f
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Guide cover horizontally over sleeve and press evenly onto its
satelettronica
seat.
Continued for all covers:
Caution
olksw
It is possible to lever cover carefully aginto its. Vseat awith
en AG a does
gen AG
ksw
-screwdriver- until »new« retaining
by
Vol ring can be installed. not
gu
d ara
se nte
– Install new retainingthoring.
ri e or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Install gearbox
l purpos
WARNING
m
at
om
in t
or
his
ate
do
riv
cum
or
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Clutch 23
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
6-speed dual clutch gearbox 02E - Edition 01.2018
satelettronica
– Remove drive plate -arrows-.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
t to the co
Note
rrectness of i
fitted.
nf
ercia
Caution
rm
m
atio
om
n in
Carefully remove the dual clutch. Take care that no parts fall
or c
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
– Remove pump shaft -A-.
rrectne
– Pump shaft is not inserted until after new clutch is installed.
Set shaft aside until then.
ss o
cial p
f inform
mer
atio
om
satelettronica
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
1.4 Installing dual clutch
p by
co Vo
by lksw
cted agen
Prote AG.
Special tools and workshop equipment required
♦ Retaining pins - T10303-
1. Clutch 25
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
6-speed dual clutch gearbox 02E - Edition 01.2018
Brief description
• The axial play of the clutch is readjusted during installation
procedure.
• To remove or install clutch, gearbox must be securely attached
n AG. Volkswagen AG do
to an assembly stand in vertical olksposition.
wage Only this way ises it
not
possible later to adjust axial
d by play
V of the clutch without error. gu
ara
e nte
ris
satelettronica
• Inside the clutch, the ularge
tho plate carrier goes through all plates. eo
ra
a
It must not slip outs of the lowest plates.
s c
ce
e
nl
an
itte
y li
• Do not install corrugated retaining rings.
erm
ab
ility
ot p
Installing
wit
, is n
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
each other.
en
ng
t.
yi Co
op py
• The butt joints of the rings should be offset relative to each . C rig
ht ht
other, i.e. not above each other.
rig by
copy Vo
by lksw
cted
– Turn rings once. They must move freely and must not bind.
agen
Prote AG.
ce
e
nl
pt
du
an
If there is no marking:
itte
y li
erm
ab
– Mark installation location of lug relative to periphery of outer
ility
ot p
plate carrier with permanent marker, as shown in illustration.
wit
, is n
h re
• During installation, the drive plate lug must always be reposi‐
hole
spec
tioned at this marked location.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
e
satelettronica
t
shown in illustration.
a
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
♦ The retaining pin remains inserted until the clutch end cover
is installed.
♦ The dual clutch must now not be rotated any more, as this can
shift the position of the retaining pin - T10303- .
1. Clutch 27
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ ,wGolfagen 2009 ➤ , GolfAG
AG. Volkswagen Plus
does2005 ➤ ...
ks
6-speed dual clutch gearbox 02E - Edition
by Vol 01.2018 not
gu
ara
ed nte
oris
– Lever out retaining ring -2- for driveautplate using
h a screwdriver e or
ac
-1- -arrow-, and lay it to one side.ss
ce
le
un
pt
an
d
itte
Caution
y li
erm
ab
ility
ot p
Only this retaining ring may be reinstalled. Never reinstall »a
wit
different« retaining ring. is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
a
o
r
satelettronica
p
c
necessary, carefully lever it off teeth of outer plate carrier using
um
r
fo
a screwdriver.
en
ng
t.
yi Co
op py
– Lay drive plate to side. t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted
Caution
agen
Prote AG.
Note
First measurement:
• Retaining pin - T10303- remains in!
– Screw universal dial gauge - VW 387- to gearbox flange.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
– Set tip of dial gauge -on hub of large plate carrier-.
ss
satelettronica
o
cial p
f
• Tip must not sit on retaining ring.
inform
mer
atio
om
n
c
i
or
n thi
e
sd
va
mately be installed:
i
o
pr
cum
r
fo
en
ng
1. Clutch 29
CC 2010 ➤ , Eos 2006 ➤en,AGolf
G. Vol2004
kswage➤n A,GGolf 2009 ➤ , Golf Plus 2005 ➤ ...
g does
6-speed dual clutch
ol swa
kgearbox 02E - Edition 01.2018
not
V y g ua
db ran
rise tee
– Insert -pump shaft-.
tho or
s au ac
s
ce
le
un
pt
Note
an
d
itte
y li
erm
ab
Slightly raise and rotate the pump shaft in the process -arrow- so
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
– Fit drive plate into dual clutch.
ss
• The projecting lug of the drive plate must be positioned be‐
o
cial p
f i
tween the colour-marked teeth of the outer plate carrier. If the
nform
markings were subsequently make, align these.
mer
atio
om
n
c
Caution
i
or
n thi
te
sd
va
satelettronica
i
o
Only the securing clip which was removed may be reinstalled.
pr
cum
r
fo
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
34 – Controls, housing
1 Electrical and electronic components
and their locations ⇒ DSG®
The electrical components are located in the gearbox.
Only the selector lever sensors control unit - J587- and the se‐
lector lever lock solenoid - N110- are located on the selector lever.
satelettronica
AG. Volkswagen AG d
⇒ page 40 lksw
agen oes
not
Vo gu
by
2 - Gearbox input speed send‐ rised ara
nte
er - G182- and oil temperature ut
ho eo
ra
sender in multi-plate clutch - ss a c
G509-
ce
le
un
pt
❑ Before sender can be
an
d
itte
y li
removed, mechatronic
erm
ab
unit for dual clutch gear‐
ility
ot p
wit
is n
moved ⇒ page 31 .
h re
ole,
spec
3 - Selector lever - E313-
urposes, in part or in wh
t to the co
❑ For information about
selector lever, see
⇒ page 62 Selector
rrectne
mechanism
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
1.1 Removing and installing mechatronic
AG.
ce
e
nl
♦ Torque wrench - V.A.G 1331-
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op
satelettronica
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Please also refer to the notes on the oil filter change regarding
»dirty oil« ⇒ page 3 .
The mechatronic unit can stick on the dowel pins when the gear‐
box is very warm. Then allow the gearbox to cool down.
– Raise vehicle. All 4 supports of lifting platform must be at same
height.
– Move selector lever to position “P”.
– Remove noise insulation and lower part of front left wheel
housing liner ⇒ General body repairs, exterior; Rep. gr. 66 ;
Removing and installing wheel housing liners; Front wheel
housing liners .
If present:
– Remove connecting hose between charge air cooler and
charge air pipe ⇒ Rep. gr. 21 ; Removing and installing parts
of charge air cooling .
Note
satelettronica
It is possible that parts having nothing to
agedo with the mechatronic
unit must be removed.lkThis a n AG. Volksw
gedepends on the vehicle's
n AG d
oes equipment.
sw
This will create enough Vo space to remove the mechatronic unit.
not
by gu
a
ed ran
ris tee
tho or
au ac
ss
ce
e
nl
pt
du
an
y li
erm
ple,
ab
ility
ot p
h re
spec
es, in part or in w
nform
ercia
at
connector.
om
ion
c
in t
or
his
ate
Note
do
priv
cum
for
en
g
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Caution
Oil runs out of cover when bolts are unscrewed. Risk of injury
from hot gearbox oil.
satelettronica
Note
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
h re
suspension links .
spec
es, in part or in w
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
at
satelettronica
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
satelettronica
his
sender arm -B- on back is no longer in gearbox housing.
ate
do
priv
c
When handling mechatronic unit, pay special attention to the
um
for
en
ng
t.
yi Co
op py
– Carefully swing mechatronic unit for dual clutch gearbox - t. C rig
gh ht
J743- downwards. yri
p by
co Vo
by lksw
cted agen
Prote AG.
Caution
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
satelettronica
a
in gearbox housing.
com
tion in
– Do not pinch wiring.
r
te o
thi
s
iva
do
– Carefully set mechatronic unit on dowel pins -arrow-. Ensure
r
rp
c
that »sender arm« locates in its -fitting position-.
um
fo
en
ng
t.
yi
– Look to see if mechatronic unit has made contact correctly.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Hook line -A- first in upper retaining lug, and then in lower
-arrows-.
– Push on connector and engage.
n AG. Volkswagen AG do
lk swage es n
o ot g
yV
– Insert new bolts -arrows- and tighten diagonally d b in several ua
ran
ir se
satelettronica
stages to 16 Nm. tho tee
or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Set new oil pump cover -A- in place and tighten bolts
-arrows- diagonally in several stages to 8 Nm.
l purpos
atio
om
o
r
rp
cu
– Reinstall any parts which may have been removed from the
o
m
f
en
ng
vehicle.
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove oil drain plug close to pendulum support -arrow-. AG. Volkswagen AG d
satelettronica
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Before screwing adapter for oil filling - VAS 6262 A- onto oil
m
at
om
his
ate
cum
for
en
ng
t.
yi Co
Note . Cop py
rig
ht ht
rig by
py
The dimension -a- is measured from the shaft (green area in the co Vo
by lksw
magnifying glass) of the adapter for oil filling - VAS 6262 A- .
cted agen
Prote AG.
satelettronica
– Check oil level and top up. ⇒ page 302
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 50 ; Noise insulation; Assembly overview - noise insulation
– Carry out basic setting.
pt
y li
rm
ility
wit
, is n
spec
– Drain oil.
l purpos
Please also refer to the notes on the oil filter change regarding
»dirty oil« ⇒ page 3 .
nform
ercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
satelettronica
20 Nm.
– Following repair work, it is not necessary to change filter again
when filling oil.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
– Remove both -covers-. aut
ho eo
ra
ss c
»Small« cover of oil pump and bolts of »large« cover must always
ce
le
un
be renewed.
pt
an
d
itte
y li
Likewise, seal of »large« cover must be renewed.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
satelettronica
and oil temperature sender in multi-plate clutch - G509- using
release tool - T10465- and pull connector off. AG. Volkswagen A n G do
wage es n
Volks ot g
by ua
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– First pull line out of lower clip -arrow I-.
es, in part or in w
t to the co
– Then remove it from second clip -arrow II- and lay to side. Do
not kink line.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove mechatronic unit for dual clutch gearbox - J743- .
satelettronica
l purpos
nform
mercia
Caution
at
om
ion
c
in t
r
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
If »arm« is damaged, mechatronic unit must be renewed. cted agen
Prote AG.
Caution
AG. Volkswagen AG d
agen oes
olksw not
byV gu
If »arm« is damaged, mechatronic unit must be renewed. rised ara
nte
ho eo
ut
satelettronica
a ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
o
r
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
le
unit.
un
pt
an
d
itte
y li
rm
ab
pe
ility
– Moisten O-rings with dual clutch gearbox oil.
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
c
– Carefully set mechatronic unit on dowel pins -arrow-. Ensure
um
fo
satelettronica
en
g
t.
yi Co
op py
– Do not pinch wiring.
. C rig
ht ht
rig by
py Vo
Be very careful: do not pinch wiring!
co lksw
by
cted agen
Prote AG.
– First press wiring for gearbox input speed sender - G182- with
oil temperature sender in multi-plate clutch - G509- into clip
-II-. Then into clip -I-.
– Press connection onto mechatronic unit.
– Set cover over mechatronic unit, being careful not to pinch any
wiring.
satelettronica
stages to 16 Nm.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
ut ra
– Set new oil pump cover -A- in place and
ss atighten bolts c
-arrows- diagonally in several stages to 8 Nm.
ce
le
un
pt
an
d
y li
rm
ab
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
le
un
pt
– Remove mechatronic unit for dual clutch gearbox - J743-
an
d
itte
y li
⇒ page 31 .
rm
ab
pe
ility
Do not pull on line!
ot
wit
, is n
h re
hole
spec
and/or pliers.
es, in part or in w
satelettronica
t to the co
Installing
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
Removing
h re
ole,
spec
– Move selector lever to position “P”.
urposes, in part or in wh
t to the co
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Removing and installing battery .
– Lay lint-free cloths on gear oil cooler and gearbox to catch
rrectne
escaping coolant.
– Clamp off coolant hoses using hose clamps - 3094- and re‐
move from cooler. ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Caution
AG. Volkswagen AG d
agen
No coolant must be allowed to drip into gearbox! Volksw
oes
not
by gu
d ara
ise nte
or eo
h
ut
Installing ss a ra
c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
satelettronica
– Set gear oil cooler -B- in place, observing O-rings -C-.
nform
ercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Caution
Do not start engine while checking coolant level if gear oil has
not yet been filled.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
♦ Used oil collector and extractor - V.A.G 1782-
l purpos
nform
ercia
satelettronica
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing oil pump
Brief description
The oil pump can be renewed without the gearbox being re‐
moved. The vehicle must be raised and any covers present
beneath the front part of the vehicle must be removed. The con‐
nection between suspension link and suspension strut does not
need to be separated. The drive shaft does not need to be re‐
moved. Do not “carry out basic adjustment” either. Only the ⇒
DSG® oil and pump cover must be renewed.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation; Assembly overview - noise in‐
sulation
– Remove lower part of front left wheel housing liner ⇒ General
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; As‐
sembly overview - front wheel housing liner .
– Place used oil collection and extraction unit - V.A.G 1782- be‐
low gearbox.
Please also refer to the notes on the oil filter change regarding
»dirty oil« ⇒ page 3 .
To gearbox manufacture date “20 September 2004”, gearboxes
were constructed with 2 plugs.
n AG. Volkswagen AG do
lkswage es n
Vo ot g
– Renew seal -arrow- for plug. d by ua
ran
ir se tee
o
– Used oil collection and extraction
auth unit - V.A.G 1782- remains or
ac
under gearbox. ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
satelettronica
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove bolts -arrows- and remove oil cooler cover -A-.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
– Remove bolts -arrows- and pull oil pump -1- off dowel pins and
co Vo
by lksw
cted
pull out oil pump drive shaft.
agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
– Push input shaft -A- for oil pump into gearbox as far as stop.
itte
y li
erm
Turn input shaft slightly whilst doing this.
ab
ility
– Always use a new metal seal -B-. ot p
wit
, is n
h re
• The 2 dowel pins -C- must be located in gearbox housing.
hole
spec
es, in part or in w
– When fitting oil pump, observe splines of input shaft and prop‐
t to the co
er seating of dowel pins.
satelettronica
Various bolts for oil pump -1-
rrectness of i
l purpos
nf
ercia
o
All 4 bolts with flat heads
rm
m
atio
m
Specified torque
o
n in
or c
thi
♦ 5 Nm + 90° (1/4 turn)
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Set new oil pump cover -A- in place and tighten new bolts
-arrows- diagonally in several stages to 8 Nm.
There is no oil in the gearbox. »New« oil must now be filled and
adjusted to the proper level ⇒ page 305 .
– Change oil and filter for dual clutch gearbox ⇒ page 301 .
– Install left wheel housing liner ⇒ General body repairs, exte‐
rior; Rep. gr. 66 ; Wheel housing liners; Assembly overview -
front wheel housing liner . gen AG
. Volkswagen AG
a does
lksw n
– Install noise insulation ⇒d byGeneral
Vo body repairs, exterior; Rep.
ot g
ua
gr. 50 ; Noise insulation;
or
is Assembly overview - noise insulation ante
e r
th eo
s au ra
c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
♦ Extractor hook - T20143-
erm
ab
ility
ot p
satelettronica
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
satelettronica
– Set lever in place and tighten to 20 Nm.
Selector shaft lever fits on splines in only one position.
– Install and adjust selector lever cable on gearbox
⇒ page 63 .
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
56
by lksw
cted agen
Rep. gr.34 - Controls, housing Prote AG.
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
6-speed dual clutch gearbox 02E - Edition 01.2018
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
satelettronica
– Unclip selector lever cover and hold aside.
rrectness of i
– Press yellow plastic wedge -arrow-.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
Handle with front push-button: d by ara
rise nte
ho eo
Button does not need to be pulled out by hand.aThe
ut push-button ra
c
engages in installation position -arrow- when the handle is pulled ss
ce
le
off.
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Unclip cover.
– Pull connector off selector cover.
nform
ercia
a
com
tio
thi
s
iva
do
r
Note
rp
cum
fo
en
ng
t.
yi
Do not press button again after removal as it will no longer be
Co
Cop py
possible to install the handle.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted
Installing
agen
Prote AG.
satelettronica
ol not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Note
l purpos
nform
ercia
at
om
io
in t
or
en
ng
t.
Continuation for all handles
yi Co
Cop py
t. rig
– Push handle fully onto selector lever and lock. gh ht
pyri by
Vo
co lksw
by
– Push sleeve downwards to lock. Prote
cted AG.
agen
Note
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
6.1.2 Handle with front push-button
ot p
satelettronica
wit
, is n
h re
With this kind of handle, the push-button cannot be pulled out.
hole
spec
There are 2 ways of moving the push-button into the installation
es, in part or in w
t to the co
position, »with« and »without« installation guard. Both of them are
described here.
Place handle »with« installation guard in installation position:
rrectness of i
When using the installation guard, make sure that it has an eyelet
l purpos
-arrow- at the front. Other types of installation guard are not suit‐
able. nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
– Holding the button down, completely push in installation guard
AG.
ce
e
nl
pt
du
an
– Carefully unclip handle trim -A- upwards.
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op
– Using a screwdriver, press the small lever -1- for the tie rod
C py
ht. rig
satelettronica
into the groove -2-. Doing this presses the push button -3- into rig ht
py by
Vo
the installation position.
co lksw
by
cted agen
Prote AG.
-I- = button pressed in
-II- = button in installation position
Note
WARNING
satelettronica
gap is visible between
knob and button. Button
locks in this position
when released. Hold
button in this position
with a cable tie or wire to
prevent it from being
pressed in.
❑ Left grip in figure: do not
press button in. Howev‐
er, if this should happen,
the knob must be dis‐
mantled and prepared
for installation
⇒ page 60 .
2 - Selector lever and selector agen
AG. Volkswagen AG d
oes
mechanism olksw not
y V gu
d b ara
❑ With selector lever lock orise nte
eo
solenoid - N110- auth
ra
s c
❑ Emergency release s
ce
le
⇒ page 57 .
un
pt
an
d
itte
y li
ab
ility
ot
wit
h re
hole
spec
selector mechanism
⇒ page 63 .
rrectness of i
tion in
❑ 3 Nm
r
te o
thi
s
iva
4 - Pin
do
r
rp
cum
❑ Removing ⇒ page 63
fo
en
ng
t.
yi
❑ Do not grease
Co
Cop py
t. rig
gh ht
yri by
62
cop Vo
by lksw
Rep. gr.34 - Controls, housing Prote
cted AG.
agen
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
6-speed dual clutch gearbox 02E - Edition 01.2018
5 - Locking plate
❑ Always renew after removing
6 - Nut
❑ 9 Nm
❑ Qty. 4
7 - Selector housing
❑ With seal
8 - Selector lever cable
❑ Do not grease cable
❑ Removing and installing ⇒ page 63
❑ Checking ⇒ page 70
❑ Adjusting ⇒ page 70
9 - Securing clip
❑ Always renew after removing
10 - Securing clip
❑ Always renew after removing
satelettronica
11 - Hexagon nut with washer
❑ 8 Nm
❑ Qty. 4 n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
o
7.2 Removing and installing selector lever th or
au ac
ss
cable up to 02.2009
ce
le
un
pt
an
d
itte
y li
erm
ab
Note
ility
ot p
wit
is n
h re
Following installation, cable must be checked for ease of move‐
ole,
t to the co
Removing
– Move selector lever to position “S” position.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
satelettronica
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
ab
securing clip.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f i
satelettronica
nform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Insert -screwdriver- from below.
satelettronica
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Clarification:
♦ -1- Push tab forwards
♦ -2- Push pin up
satelettronica
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
f in
Installing
form
mer
atio
n
c
– Route selector lever cable without stress. Also insert into cable
or
n thi
e
sd
iva
cum
r
fo
en
ng
– Insert cable into bearing and insert pin from above, down‐ AG. Volkswagen AG d
wards through eye. ksw
agen oes
not
satelettronica
Vol
by gu
– Check selector lever cable for ease of movement rised ara
nte
⇒ page 70 . ut
ho eo
ra
s a c
– Then insert new securing clip. s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
or
– Attach cable with new securing clip on cable support bracket
m
m
atio
of selector mechanism.
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
satelettronica
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
7.3 Checking selector lever cable
Brief description
rrectne
The ease of movement is checked on the cable. Selector lever
s
cable must be removed from gearbox so that its ease of move‐
s o
ment can be checked. Put removed end down so it does not rub
cial p
f in
against anything.
form
mer
satelettronica
atio
The selector lever must be moved and then the cable must be
om
n
c
i
or
n thi
e
sd
iva
o
pr
c
Do not grease connections of cable!
um
r
fo
en
ng
t.
yi
Check
Co
Cop py
ht. rig
– Move selector lever to position »P«.
rig ht
py by
co Vo
by lksw
– Remove cable from lever on gearbox.
cted agen
Prote AG.
ce
le
un
pt
– Then push lever »backwards«.
an
d
itte
y li
satelettronica
erm
ab
“P” is in second detent.
ility
ot p
wit
is n
h re
ole,
Note
spec
urposes, in part or in wh
t to the co
♦ Raise vehicle, to be sure that the gearbox is actually in
“P” (parking lock engaged). It should not be possible to turn
both front wheels together in the same direction.
rrectne
♦ Gearbox is also in “P” if vehicle cannot be pushed although its
wheels are free to turn.
ss o
cial p
f inform
mer
atio
om
n
– Install cable with loosened adjusting screw -arrow- and new
c
i
or
n
securing clips -A- and -B-.
thi
te
sd
iva
o
r
cum
r
fo
t.
yi Co
op
In this way the ⇒ inner cable of the Bowden cable finds it optimal C py
ht. rig
position. rig ht
py by
co Vo
by lksw
– Tighten adjusting screw to 13 Nm. cted agen
Prote AG.
satelettronica
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. gen AG
. Volkswagen AG
d wa oes
olks not
8.2 Selector lever in “N” position and ignition ed
byV gu
ara
nte
ris
switched on au
tho eo
ra
ss c
• Brake pedal not depressed:
ce
le
un
pt
an
d
y li
rm
with the lock button pressed. Solenoid for selector lever lock
ab
pe
ility
blocks selector lever.
ot
wit
, is n
spec
Solenoid for selector lever lock releases selector lever. It is pos‐
es, in part or in w
When the selector lever is shifted into the Tiptronic gate, the se‐
m
lector lever position display in the dash panel insert must change
a
com
ti
from “P R N D S” to “6 5 4 3 2 1”.
on in
r
te o
thi
do
r
rp
cum
en
ng
t.
yi Co
8.5 Selector lever position indicator Cop py
t. rig
gh ht
yri by
Simultaneous illumination of all selector lever position display cop Vo
by lksw
cted
segments indicates gearbox emergency running mode.
agen
Prote AG.
WARNING
satelettronica
ut ra
❑ Right knob inssfigure: first
a c
pull button far enough
ce
le
un
pt
out of knob until a small
an
d
itte
y li
erm
ab
knob and button. Button
ility
ot p
wit
is n
h re
ole,
spec
pressed in with a cable
urposes, in part or in wh
tie or wire.
t to the co
❑ Left grip in figure: button
engages in installation
rrectne
handle.
mer
atio
⇒ page 58
n
c
i
or
n thi
e
sd
iva
cum
r
fo
cable
en
ng
t.
yi Co
❑ With selector lever lock Cop py
solenoid - N110-
t. rig
gh ht
pyri by
❑ Do not grease cable
o Vo
by c lksw
cted agen
Prote
❑ Removing and installing
AG.
⇒ page 74
❑ Checking ⇒ page 70
❑ Adjusting ⇒ page 70
3 - Bolt
❑ 8 Nm
4 - Hexagon flange nut
❑ 8 Nm
❑ Qty. 4
5 - Selector housing
6 - Locking plate
❑ Always renew after removing
7 - Locking plate
❑ Always renew after removing
ce
e
pt
du
an
itte
y li
erm
ab
ility
ot p
Brief description
wit
, is n
h re
Selector mechanism and selector lever cable are not allowed to
hole
spec
be separated from one another. Both are removed together with
es, in part or in w
t to the co
In the interior, the centre console must be removed.
satelettronica
The heat shield beneath the vehicle must be removed.
rrectness of i
The selector mechanism with selector lever cable can be re‐
l purpos
nform
mercia
at
Note
om
ion
c
in t
or
his
Following installation of selector mechanism, selector lever cable
ate
do
riv
cum
for
en
ng
t.
yi
Removing
Co
Cop py
t. rig
gh ht
yri by
– Move selector lever to position “P”. op Vo
by c lksw
cted agen
Prote
– Remove selector lever handle ⇒ page 58 .
AG.
ce
le
un
pt
an
d
itte
y li
erm
ab
Note
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
– Remove nuts -arrows- inside vehicle.
– If fitted, remove bracket -A-.
rrectne
– Remove selector mechanism -B- together with selector lever
satelettronica
s
cable and selector housing downwards.
s o
cial p
f
Installing
inform
mer
n
c
i
or
n thi
e
Note
t
sd
iva
o
pr
cum
r
fo
t.
yi Co
op
♦ Do not grease selector lever cable. C py
t. rig
gh ht
yri by
♦ Specified torques ⇒ page 73 . op Vo
by c lksw
cted agen
Prote AG.
– Install heat shield beneath selector mechanism ⇒ General
body repairs, exterior; Rep. gr. 66 ; Underbody cladding; As‐
sembly overview - underbody cladding .
– Install centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; Centre console; Removing and installing centre con‐
sole .
– Install selector lever handle ⇒ page 58 .
– Adjust selector lever cable ⇒ page 70 .
– Check selector mechanism ⇒ page 72 .
– Install complete air filter housing:
♦ Petrol engine: ⇒ Rep. gr. 24 ; Air filter; Removing and instal‐
ling air filter housing
♦ Diesel engine: ⇒ Rep. gr. 23 ; Air filter; Removing and instal‐
ling air filter housing
satelettronica
hicle wiring harness.
– Remove air filter housing.
. Volkswagen AG
a gen AG does
♦ Petrol engine: ⇒ Rep. gr. 24 ; Air filter; Removing and Vol instal‐
ksw not
gu
ling air filter housing ed
by ara
nte
is
or eo
♦ Diesel engine: ⇒ Rep. gr. 23 ; Air filter; Removing
au
th and instal‐ ra
ling air filter housing ss c
ce
e
nl
pt
du
an
– Remove securing clips -A- and -B-. Securing clips must be
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
Use pliers to remove the securing clip -B- on the cable support
hole
spec
bracket. Do not use a sharp-edged lever. The selector lever cable
es, in part or in w
t to the co
– Then a long cord must be attached to the end of the Bowden
cable. The cord is needed to guide the Bowden cable between rrectness of i
the tunnel and heat shield during installation.
l purpos
nform
ercia
– Remove 4 bolts.
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
– Attach Bowden cable to cord which was drawn into the pas‐
senger compartment during removal.
satelettronica
– Carefully guide selector mechanism with Bowden cable
through opening in centre tunnel.
– Have the second mechanic pull cord with Bowden cable
through tunnel from engine compartment until Bowden cable
can be attached to support bracket.
olkswagen AG
en AG. V
– Remove cord from Bowden cable.
olks
wag does
not
y V gu
d b ara
ise nte
– Secure selector mechanism
uthor
to selector housing using 4 bolts. eo
a ra
s c
Specified torque: 8 Nm s
ce
e
nl
pt
du
y li
ab
sole .
ility
ot p
wit
, is n
t to the co
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
an
d
y li
-steering rack- and -both suspension links-.
rm
ab
pe
ility
ot
wit
, is n
h re
Special tools and workshop
hole
equipment required
spec
es, in part or in w
satelettronica
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Support - 10-222A-
♦ Adapter - 10-222A/3-
♦ Adapter - 10 - 222 A /18-
♦ Gearbox support - 3282-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
♦ Socket insert - T10035-
ot p
wit
is n
h re
ole,
satelettronica
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
i
or
n thi
te
o
pr
cum
r
en
ng
t.
yi Co
♦ Adapter - 10 - 222 A /8- Cop py
t. rig
gh ht
yri
♦ If no hose clamps to 40 mm - 3093- are available, use hose p by
o Vo
by c
clamps to 25 mm - 3094- .
lksw
cted agen
Prote AG.
♦ Engine and gearbox jack - V.A.G 1383 A- or engine and gear‐
box jack - VAS 6931-
Removing:
– Raise vehicle. All 4 supports of lifting platform must be at same
height.
– Move selector lever to position »P«.
– Remove complete air filter housing ⇒ Rep. gr. 24 ; Removing
and installing air filter .
satelettronica
connector.
– Remove starter -A- ⇒ Electrical system; Rep. gr. 27 ; Starter;
Removing and installing starter .
It is advisable to remove the »lower« bolt first.
– Unbolt earth strap from bracket.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
d
– Remove selector lever cable from gearbox. orise nte
h eo
ut ra
Use pliers to remove the securing clip on the cable support
ss abrack‐ c
et. Do not use a sharp-edged lever, as the rubber grommet on the
ce
le
un
pt
cable could be damaged.
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
f inform
n
c
n thi
e
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
satelettronica
These tools are appropriate for this.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
satelettronica
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
cum
fo
housing liners .
en
ng
t.
yi Co
op
– Unbolt wiring retainer from front of »black« gearbox cover (2
C py
t. rig
gh
nuts M6).
ht
pyri by
Vo
o
by c lksw
Specified torque: 10 Nm
cted agen
Prote AG.
– Pull connector -1- off oil level and oil temperature sender -
G266- .
satelettronica
AG. Volkswagen AG d
agen oes
– Secure drive shaft to suspension strut with tensioning strap
olks -
w not
yV gu
T10038- . se
d b ara
nte
i
or eo
The surface protection of the shafts must not be adamaged.
ut
h
ra
ss c
– Remove filler pieces from upper edges of both wings
ce
e
nl
pt
du
an
– If there are hose and cable connections in area of engine sup‐
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
satelettronica
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Caution
satelettronica
– Move engine and gearbox jack - V.A.G 1383 A- under gearbox
and support gearbox. Do not raise.
The gearbox is separated from the engine in this position.
– Remove last engine/gearbox connecting bolt.
– Press gearbox off engine while »observing selector lever ca‐
ble«, and lower gearbox.
AG. Volkswagen AG d
Transporting gearbox and securing to assembly stand olkswagen oes
not
⇒ page 283 . db
yV gu
ara
e nte
ris
Install gearbox ⇒ page 273 . utho eo
ra
a c
ss
ce
e
pt
du
an
itte
y li
erm
ab
ility
ot p
Brief description
wit
, is n
h re
The gearbox is removed downwards separately. The engine re‐
hole
spec
mains in the vehicle. »From above«
es, in part or in w
The battery, air filter and starter are removed. The coolant hoses t to the co
must be clamped off. Support engine and gearbox before left
subframe mounting is unbolted.
rrectness of i
»From below«
l purpos
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
In any case, locating pins - T10096- are necessary.
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
If the position of the -subframe- is not fixed with the pins, the
es, in part or in w
t to the co
wheels must later be aligned.
In this case, wheel alignment would be unnecessary and costly
additional work! Save yourself this work and your customer the
rrectness of i
expense!
l purpos
nf
ercia
satelettronica
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
ksw not
satelettronica
Vol
by gu
d ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
♦ Support - 10-222A-
inform
mer
♦ Adapter - 10-222A/3-
atio
om
i
or
n thi
e
sd
iva
o
pr
cum
en
ng
t.
yi
♦ Insert tool, 18 mm - T10179-
Co
Cop py
t. rig
gh ht
Special tools and workshop equipment required yri
p by
o Vo
by c lksw
cted
♦ Bracket - T10346-
agen
Prote AG.
ce
le
un
pt
♦ Socket insert - T10035-
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
Special tools and workshop equipment required
mer
atio
m
n
c
i
or
n
♦ Adapter - 10 - 222 A /8-
thi
te
sd
iva
o
r
cum
r
fo
clamps to 25 mm - 3094- .
en
ng
t.
yi Co
op
♦ Engine and gearbox jack - V.A.G 1383 A-
py
satelettronica
t. C rig
gh ht
yri by
Removing: cop Vo
by lksw
cted agen
Prote
– Raise vehicle. All 4 supports of lifting platform must be at same
AG.
height.
– Move selector lever to position »P«.
– Remove both front wheels.
– Remove complete air filter housing ⇒ Rep. gr. 24 ; Removing
and installing air filter .
– Remove battery and -battery box- ⇒ Rep. gr. 27 ; Battery;
Removing and installing battery .
satelettronica
Both securing clips must be later renewed when cable is adjusted.
Remove cable with great care from cable support bracket on
gearbox. Do not bend it. agen
AG. Volkswagen AG d
o w es n
olks o
Cable may also be pushedd b slightly backwards out of cable support
yV t gu
ara
bracket and removedoriselater when gearbox is lowered. But then nte
eo
observe cable when
au
th
lowering gearbox. ra
ss c
During later installation, do not clip »small« securing clips on until
ce
e
nl
pt
du
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
M6 nuts).
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
AG. Volkswagen AG d
– Disconnect wire -1- from electronics box. agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
satelettronica
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Disconnect earth cable -2-.
rrectness of i
– Disconnect electrical connector -3-.
l purpos
This wiring harness will later be removed together with the sub‐
frame. This way, you can avoid time-consuming work on the
nform
ercia
a
com
tio
– Remove all upper connecting bolts from engine and gearbox.
n in
r
thi
s
iva
do
– Remove filler pieces from upper edges of both wings
r
rp
cum
fo
t.
yi Co
eyes, remove them now. . Cop py
rig
ht ht
rig by
py
– Now separate steering from steering column.
co Vo
by lksw
cted agen
Prote AG.
Refer to ⇒ Running gear, axles, steering; Rep. gr. 48 ; Removing
and installing steering rack to see what must be done.
In any case, return the steering wheel to the straight-ahead po‐
sition. Engage steering wheel lock. Notes on tightening the bolt
can also be found in these instructions.
– Separate steering box from steering column.
It is advisable to now do all the work which must be done »be‐
neath« the car. This will avoid having the weight of the engine
carried by the support bar and, consequently, by the body, for »a
long time«.
– Remove noise insulation and lower part of front left wheel
housing liner ⇒ General body repairs, exterior; Rep. gr. 66 ;
Removing and installing wheel housing liners; Front wheel
housing liners .
– Remove left wheel housing liner.
– If fitted, remove the heat shield over the right-hand drive shaft.
Tightening torque ⇒ Rep. gr. 40 ; Repairing drive shafts
ce
le
un
pt
very good for this.
an
d
itte
y li
rm
satelettronica
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Secure both drive shafts to suspension struts using tensioning
straps - T10038- .
rrectness of i
– Unbolt ⇒ pendulum support from gearbox.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Next remove -subframe- together with -pendulum support- and . Cop py
-both suspension links- and -steering-.
t rig
gh ht
pyri by
Vo
co
For information on how to remove the -subframe-, refer to ⇒ Rep.
by lksw
cted agen
Prote
gr. 40 . If the job is done correctly, the subframe can be removed
AG.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
– Fit retainer - T10346- on longitudinal member.
te
sd
a
satelettronica
iv
o
r
cum
r
fo
en
ng
satelettronica
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
– Remove all bolts -1- and -2- for bracket -A-. wit
, is n
h re
– Then lower engine and gearbox slightly using spindles of sup‐
hole
spec
port bracket - 10 - 222 A- until bracket can be removed.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
About 3 turns are sufficient to remove bracket -arrow-.
nl
pt
du
an
itte
The gearbox is separated from the engine in this position.
y li
erm
ab
ility
– Set up gearbox support - 3282- with adjustment plate -
ot p
wit
3282/42 A- .
, is n
h re
hole
– Move engine and gearbox jack - V.A.G 1383 A- under gearbox
spec
and support gearbox. Do not raise. es, in part or in w
t to the co
– Remove remaining engine/gearbox connecting bolts.
– Press gearbox off engine while »observing selector lever ca‐
rrectness of i
ble«, and lower gearbox.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
with 1.4 l petrol engine
te
sd
iva
o
r
rp
cu
Brief description
o
m
f
en
ng
t.
yi
satelettronica
Co
The gearbox is removed downwards separately. »From above« t. Cop py
rig
gh ht
yri
The battery, air filter and starter are removed. The coolant hoses p by
co Vo
must be clamped off. Left subframe mounting is removed and
by lksw
cted agen
Prote
engine and gearbox supported.
AG.
»From below«
Remove -subframe- together with -pendulum support-,
-steering rack- and -both suspension links-.
If the position of the -subframe- is not fixed with the pins, the
wheels must later be aligned.
In this case, wheel alignment would be unnecessary and costly
additional work! Save yourself this work and your customer the
expense!
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
ut
satelettronica
a ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Support - 10-222A-
♦ Adjustment plate - 3282/42 A-
♦ Adapter - 10 - 222 A /8-
♦ Adapter - 10-222A/3-
♦ Gearbox support - 3282-
♦ Insert tool, 18 mm - T10179-
satelettronica
t eo
au ra
– Remove battery and s-battery
s box- ⇒ Rep. gr. 27 ; Battery; c
Removing and installing battery .
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
satelettronica
cable has been checked and adjusted ⇒ page 70 .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
o
– Clamp off coolant hoses ausing
ut
h hose clamps to 40 mm - 3093- eo
ra
or hose clamps to 25 mm
ss - 3094- and remove. c
ce
le
un
pt
– Unbolt wiring retainer from front of »black« gearbox cover (2
an
d
itte
nuts M6).
y li
rm
ab
pe
connector. wit
, is n
h re
hole
One bolt is located in hole for starter at the height of the solenoid.
Socket - T10061- , 18 mm insert - T10179- or insert tool -
rrectness of i
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
satelettronica
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
Refer to ⇒ Running gear, axles, steering; Rep. gr. 48 ; Removing
hole
spec
and installing steering rack to see what must be done.
es, in part or in w
t to the co
In any case, first return the steering wheel to the straight-ahead
position. Engage steering wheel lock. Notes on tightening the bolt
can also be found in these instructions.
rrectness of i
– Separate steering box from steering column.
l purpos
atio
not raise.
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
satelettronica
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
satelettronica
removed.
. Volkswagen AG
If the position of the subframe was not fixed, the kwheels
wage must now
n AG does
be aligned. Vol s not
gu
by d ara
ise nte
⇒ Running gear, axles, steering; Rep.thgr.
or 40 ; Locating subframe eo
and brackets . ss
au ra
c
ce
le
pt
an
d
itte
y li
erm
ab
– After removing a bolt -1-, immediately screw in a locating pin
ility
ot p
- T10096- -2-.
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
le
cable ties or a pair of tensioning straps - T10038- are therefore
un
pt
an
very good for this.
d
itte
y li
rm
ab
The air pipe and the electric coolant pump in front of the gearbox
pe
ility
are still »in the way«.
ot
wit
, is n
h re
– Remove brackets for air pipe and coolant pump.
hole
spec
This is sufficient and creates space to support the gearbox. The
es, in part or in w
t to the co
coolant circuit and charge air pipe do not need to opened or sep‐
arated, respectively.
– Set up gearbox support - 3282- with adjustment plate -
rrectness of i
3282/42 A- .
l purpos
nform
ercia
a
com
tio
satelettronica
n in
– Remove remaining engine/gearbox connecting bolts.
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
th
♦ Support - s10
au - 222 A- ra
c
s
ce
pt
an
d
itte
ab
ility
♦ Adapter - 10-222A/3-
ot p
wit
is n
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
102
cted agen
Prote
Rep. gr.34 - Controls, housing
AG.
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
6-speed dual clutch gearbox 02E - Edition 01.2018
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
wit
is n
♦ Bracket - T10346-
h re
ole,
spec
t to the co
Removing:
o
cial p
f inform
height.
atio
om
n
c
n thi
te
sd
iva
o
pr
cum
Note
r
fo
en
ng
t.
yi Co
op
After loosening centre bolt, do not lower vehicle to ground again.
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
– Remove complete air filter housing ⇒ Rep. gr. 24 ; Removing
pt
du
an
and installing air filter .
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove battery and battery tray ⇒ Rep. gr. 27 ; Battery; Re‐
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
satelettronica
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
– Remove cable with great care from cable support bracket on
y li
erm
ab
gearbox. Do not bend cable.
ility
Cable can also be removed later on when gearbox is being low‐ ot p
wit
is n
h re
ered. Then observe cable whilst lowering gearbox.
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
– Clamp off coolant hoses using hose clamps to 40 mm - 3093-
cial p
f in
or hose clamps to 25 mm - 3094- and remove.
form
mer
atio
– Remove charge air pipe ⇒ Rep. gr. 21 ; Removing and in‐
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi
satelettronica
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
m
satelettronica
o
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
e
nl
pt
housing liners .
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
charge air pipe ⇒ Rep. gr. 21 ; Removing and installing parts
of charge air cooling .
rrectness of i
l purpos
nform
ercia
satelettronica
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
g
t.
yi Co
fan cover . Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Pull connector -1- off oil level and oil temperature sender -
G266- .
– Remove left drive shaft ⇒ Rep. gr. 40 ; Removing and instal‐
ling drive shafts .
satelettronica
– Use tensioning strap - T10038- to secure drive shafts on sus‐
. Volkswagen AG
pension strut. ksw agen AG does
ol not
yV gu
The surface protection of ithe
se shafts must not be damaged.
db ara
nte
r
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
satelettronica
Specified torque: 30 Nm
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
s a ac
– Unscrew lower bracket for diesel particulate filter from engine
s
ce
e
-2- and pull bracket off threaded pins ⇒ Rep. gr. 26 ; Remov‐
nl
pt
du
an
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
spec
t to the co
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
ut ra
satelettronica
s a c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
member.
in t
or
his
ate
do
priv
Caution
um
for
en
ng
t.
yi Co
Do not place support bracket on the wings, as this may cause Cop py
t. rig
damage. opyri
gh by
Vo
ht
by c lksw
cted agen
Prote AG.
– Support engine and gearbox with support bracket - 10 - 222
A- and hooks - 10 - 222 A /10- . Do not raise.
– Remove all bolts -1- and -2- for bracket -A-.
– Then lower engine/gearbox using spindles of support bracket
- 10 - 222 A- until bracket -A- can be removed.
At most, 5 turns of each spindle should be sufficient to remove
bracket.
In many cases, the spindle does not need to be lowered further
for the later removal of the gearbox.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove all connecting bolts except one which is in an easily
l purpos
nform
ercia
Bolt -1- = M6 X 20
m
a
com
tio
– Secure engine support - 3300 A- on bracket - T10346- .
n in
r
te o
thi
– Set engine support against engine crank case.
s
iva
do
satelettronica
r
rp
c
– Push engine/gearbox far enough forward until there is enough
um
fo
en
g
t.
yi Co
Cop py
t. rig
gh ht
yri by
Note cop Vo
by lksw
cted agen
Prote AG.
When moving engine/gearbox assembly, make sure that no con‐
necting lines, hoses or radiator are kinked or damaged.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Special tools and workshop
equipment required
rrectness of i
l purpos
nf
ercia
orm
satelettronica
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Support - 10 - 222 A-
♦ Adjustment plate - 3282/42 A-
♦ Adapter - 10 - 222 A /8-
♦ Adapter - 10-222A/3-
♦ Gearbox support - 3282-
♦ Insert tool, 18 mm - T10179-
ce
le
un
pt
an
d
y li
rm
height.
ab
pe
ility
ot
wit
, is n
h re
– Remove complete air filter housing ⇒ Rep. gr. 24 ; Removing
hole
spec
and installing air filter .
es, in part or in w
t to the co
– Remove battery and battery tray ⇒ Rep. gr. 27 ; Battery; Re‐
moving and installing battery .
rrectness of i
l purpos
satelettronica
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
an
d
satelettronica
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
m
satelettronica
o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
satelettronica
– Unbolt wiring retainer from front of »black« gearbox cover (2
nuts M6).
Specified torque: 10 Nm
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
– Pull connector -1- off oil level and oil temperature sender -
erm
ab
G266- .
ility
ot p
wit
is n
– Unbolt left and right drive shaft from gearbox ⇒ Rep. gr. 40 ;
h re
ole,
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Secure both drive shafts on suspension strut with tensioning
urposes, in part or in wh
belts - T10038- .
t to the co
The surface protection of the shafts must not be damaged.
rrectness o
cial p
satelettronica
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
r
cum
r
fo
t.
yi Co
op
⇒ Running gear, axles, steering; Rep. gr. 40 ; Removing and
C py
t. rig
gh
installing subframe with steering rack
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
satelettronica
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
bevel box flange with paint.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
shield.
es, in part or in w
t to the co
– Remove filler pieces from upper edges of both wings
– If there are hose and cable connections in area of engine sup‐
port eyes for support bracket - 10-222 A- , remove these now. rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
satelettronica
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
en
ng
t.
member.
yi Co
Cop py
ht. rig
rig ht
py by
Caution co Vo
by lksw
cted agen
Prote AG.
Do not place support bracket on the wings, as this may cause
damage.
ce
e
nl
pt
du
an
itte
– Remove all connecting bolts except one which is in an easily
y li
erm
ab
accessible place between engine and gearbox.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
at
– Set up gearbox support - 3282- with adjustment plate -
om
ion
3282/42 A- .
c
in t
or
his
te
do
riv
cum
for
en
g
t.
yi
satelettronica
Co
Cop py
– Remove last engine/gearbox connecting bolt.
t. rig
gh ht
pyri by
Vo
o
by c
– Press gearbox off engine while »observing selector lever ca‐
lksw
cted agen
Prote
ble«, and lower gearbox.
AG.
satelettronica
ris tee
tho or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
If the position of the -subframe- is not fixed with the pins, the
wit
, is n
h re
hole
spec
In this case, wheel alignment would be unnecessary and costly
es, in part or in w
additional work! Save yourself this work and your customer the
t to the co
expense!
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
satelettronica
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
♦ Support - 10-222A-
i
or
n thi
te
sd
a
o
pr
cum
r
fo
t.
clamps to 25 mm - 3094- .
yi Co
Cop py
t. rig
♦ Adapter - 10 - 222 A /18- gh ht
pyri by
Vo
co lksw
by
♦ Gearbox support - 3282- Prote
cted AG.
agen
satelettronica
– Remove selector lever cable from gearbox.
Use pliers to remove the washer on the cable support bracket. Do
not use a sharp-edged lever, as the rubber grommet on the cable
could be damaged.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
Both securing clips must be later renewed when cable is adjusted. wit
is n
h re
Remove cable with great care from cable support bracket on
ole,
t to the co
f inform
mer
atio
om
i
or
sd
iva
cum
r
fo
nuts M6).
en
ng
t.
yi Co
op
– Release mechatronic unit connector by turning and pull off C py
t. rig
connector.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
– Disconnect wire -1- from electronics box.
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
satelettronica
l purpos
nform
mercia
a
com
tion in
– Disconnect earth cable -2-.
r
te o
thi
– Disconnect electrical connector -3-.
s
iva
do
r
rp
This wiring harness will later be removed together with the sub‐ cum
fo
en
ng
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
or
satelettronica
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
tion in
r
thi
do
r
rp
cum
en
ng
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
satelettronica
ion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– If fitted, remove the heat shield over the right-hand drive shaft.
Tightening torque ⇒ Rep. gr. 40 ; Repairing drive shafts
AG. Volkswagen AG d
– Unbolt drive shafts from gearbox and carefully
olks
walay
gento side. oes
not
yV gu
db ara
ir se nte
ho eo
aut ra
ss c
ce
le
un
pt
satelettronica
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
-both suspension links- and -steering-.
Valuable information concerning the installation of the
-subframe- can be found in ⇒ Rep. gr. 40 . It is recommended to
rrectne
read this information »before« removing gearbox. Then it will be
clear how to fix the position of the -subframe- so it can then be
s
removed as shown in this figure.
s o
cial p
f in
If the position of the subframe was not fixed, the wheels must now
form
mer
be aligned.
atio
m
n
c
i
or
and brackets .
thi
te
sd
va
o
pr
cum
r
fo
en
ng
t.
yi
– After removing a bolt -1-, immediately screw in a locating pin
Co
op py
- T10096- -2-. t. C rig
gh ht
pyri by
Once the subframe has been removed, the engine and gearbox
co Vo
by lksw
cted
must be supported.
agen
Prote AG.
– A small cover plate is located above the right drive shaft flange
on the intermediate plate for engine and gearbox. Remove
cover plate -A-.
– Set up gearbox support - 3282- with adjustment plate -
3282/42 A- . AG. Volkswagen AG d
agen oes
lksw not
– Move engine and gearbox jack - V.A.G 1383 A- under gearbox byV
o gu
ara
and support gearbox. Do not raise. rised
nte
ho eo
ut
The gearbox is separated from the engine in this position.
ss a ra
c
ce
le
– Remove remaining engine/gearbox connecting bolts.
un
pt
an
d
itte
y li
– Press gearbox off engine while »observing selector lever ca‐
erm
ab
ble«, and lower gearbox.
ility
ot p
wit
is n
Transporting gearbox and securing to assembly stand
h re
⇒ page 283 .
ole,
spec
urposes, in part or in wh
t to the co
10.7 Removing gearbox, Golf 2009 ► 2.0 l
rrectne
diesel engine
satelettronica
Brief description
ss o
cial p
f
The gearbox is removed downwards separately. »From above«
inform
mer
The battery, air filter and starter are removed. Wiring harness of
atio
m
n
c
i
or
n thi
and gearbox must be supported before the left subframe mount‐
te
sd
va
ing is removed.
i
o
pr
cum
r
fo
»From below«
en
ng
t.
yi Co
op
Remove -subframe- together with -pendulum support-,
C py
ht. rig
-steering rack- and -both suspension links-.
rig ht
py by
co Vo
by lksw
cted
Both drive shafts are disconnected from gearbox and left installed
agen
Prote AG.
in wheel bearing housings. They are only swivelled to one side
and left on vehicle.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Special tools and workshop
rrectness of i
equipment required
l purpos
nform
mercia
at
satelettronica
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Support - 10-222A-
♦ Adjustment plate - 3282/42 A-
♦ If no hose clamps to 40 mm - 3093- are available, use hose
clamps to 25 mm - 3094- .
♦ Adapter - 10 - 222 A /18-
♦ Gearbox support - 3282-
♦ Insert tool, 18 mm - T10179-
ce
e
nl
pt
du
an
and installing starter
itte
y li
satelettronica
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
te
do
priv
cum
or
en
g
t.
yi Co
op
could be damaged. C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
pt
an
d
frame.
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f
– Disconnect wire -1- from electronics box.
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
le
un
heat shield.
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Remove all upper engine/gearbox connecting bolts.
rrectness of i
These tools are appropriate for this.
l purpos
nform
mercia
a
com
tion in
satelettronica
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
satelettronica
ss c ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
satelettronica
– If fitted, remove the heat shield over the right-hand drive shaft.
Tightening torque ⇒ Rep. gr. 40 ; Repairing drive shafts
– Unbolt drive shafts from gearbox and carefully lay to side.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
t to the co
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– A small cover plate is located above the right drive shaft flange
satelettronica
on the intermediate plate for engine and gearbox. Remove
cover plate -A-. wage
n AG. Volkswagen AG do
e ks s no
Vol t gu
– Set up gearbox support - 3282- with adjustment
ed
by plate - ara
3282/42 A- . horis nte
eo
t
au ra
– Move engine and gearbox jack - sV.A.G
s 1383 A- under gearbox c
and support gearbox. Do not raise.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
– Remove remaining engine/gearbox connecting bolts.
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
⇒ page 283 .
Install gearbox ⇒ page 273 .
rrectness of i
l purpos
wheel drive)
m
at
om
Brief description
on
c
in t
or
»From above«
do
priv
cum
or
The battery, air filter and starter are removed. The coolant hoses
f
en
ng
t.
yi
must be clamped off. Left subframe mounting is removed and
Co
op py
engine and gearbox supported.
. C rig
ht ht
rig by
py Vo
»From below«
co lksw
by
cted agen
Prote AG.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
♦ Support - 10 - 222 A-
in t
or
his
te
do
priv
cum
or
en
ng
t.
yi Co
♦ Hose clamps up to 40 mm - 3093- if available, or hose clamps Cop py
ht. rig
up to 25 mm - 3094- rig ht
py by
co Vo
by lksw
♦ Gearbox support - 3282- Prote
cted AG.
agen
ce
e
nl
pt
– Remove complete air filter housing ⇒ Rep. gr. 24 ; Removing
du
an
itte
y li
erm
ab
ility
– Unbolt earth strap from bracket.
ot p
wit
, is n
h re
hole
spec
satelettronica
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
atio
om
sd
iva
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
satelettronica
– Unbolt coolant line from engine -1- and -2-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
The following tools are appropriate for this:
– Remove noise insulation and lower part of front left wheel
rrectne
housing liner ⇒ General body repairs, exterior; Rep. gr. 66 ;
Removing and installing wheel housing liners; Front wheel
s
housing liners .
s o
cial p
f inform
mer
atio
satelettronica
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
satelettronica
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
The -seal- in the propshaft must not be damaged. If seal is dam‐
aged, propshaft must be renewed.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
– Remove heat shield above right drive shaft -1- ⇒ Rep. gr. 40 ;
t.
yi Co
op
Heat shields for drive shafts . C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
satelettronica
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Caution
AG. Volkswagen AG d
agen oes
olksw not
y V gu
b ara
– Then lower engine/gearbox assembly to dimension rise
d -a- using nte
spindle of support bracket - 10 - 222 A- . ut ho eo
ra
s a c
s
Dimension -a- = about 20mm
ce
le
un
pt
an
d
itte
y li
rm
ab
satelettronica
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Remove bracket -arrow-.
l purpos
nform
ercia
3282/42 A- .
a
com
tion in
– Move engine and gearbox jack - V.A.G 1383 A- under gearbox
r
te o
thi
and support gearbox. Do not raise.
s
iva
do
r
rp
en
ng
t.
– Remove last engine/gearbox connecting bolt.
yi Co
Cop py
t. rig
– Press gearbox off engine while »observing selector lever ca‐
gh ht
yri by
ble«, and lower gearbox.
cop Vo
by lksw
cted agen
Prote AG.
Transporting gearbox and securing to assembly stand
⇒ page 283 .
Install gearbox ⇒ page 273 .
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
b
If the position of the rise-subframe- is not fixed with the pins, the
d ara
nte
wheels must later uthobe aligned. eo
ra
s a c
In this case, wheel alignment would be unnecessary and costly
s
ce
le
additional work! Save yourself this work and your customer the
un
pt
an
d
expense!
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
satelettronica
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Support - 10-222A-
♦ Adapter - 10-222A/3-
♦ Additional hook - 10-222A/13-
♦ Gearbox support - 3282-
♦ Adjustment plate - 3282/42 A-
♦ Insert tool, 18 mm - T10179-
Special tools and workshop equipment required
♦ Tools without illustration:
♦ Pin - 3282/29-
♦ Socket insert - T10035-
♦ Support - 3282/59-
♦ If no hose clamps to 40 mm - 3093- are available, use hose
clamps to 25 mm - 3094- .
♦ Engine and gearbox jack - V.A.G 1383 A-
Removing:
– Raise vehicle. All 4 supports of lifting platform must be at same
height.
Note
AG. Volkswagen AG d
agen oes
o lksw not
y V gu
d b ara
– rise
Remove battery and h-battery box- ⇒ Rep. gr. 27 ; Battery; nte
o
satelettronica
eo
Removing and installing
s aut
battery . ra
c
s
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Removing
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
sd
iva
o
r
rp
cu
m
f
t.
yi
could be damaged.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
satelettronica
ara
18 mm - T10179- is especially goodrisefor this purpose. nte
ho t eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Disconnect -wiring harness- coming »from below« from sub‐
ility
ot p
frame.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
eyes, remove them now.
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Refer to ⇒ Running gear, axles, steering; Rep. gr. 48 ; Removing
es, in part or in w
t to the co
In any case, first return the steering wheel to the straight-ahead
position. Engage steering wheel lock. Notes on tightening the bolt
rrectness of i
can also be found in these instructions.
l purpos
satelettronica
– Remove filler pieces from upper edges of both wings
nf
ercia
o
– If there are hose or wiring connections near the engine lifting
rm
m
atio
eyes, remove them now.
om
n in
or c
thi
– Support engine and gearbox with support bracket - 10 - 222
te
sd
iva
o
r
rp
cu
adapter - 10 - 222 A /13- . Do not raise.
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– If fitted, remove the heat shield over the right-hand drive shaft.
Tightening torque ⇒ Rep. gr. 40 ; Repairing drive shafts
– Unbolt drive shafts from gearbox and carefully lay to side.
The surface protection of the shafts must not be damaged. Plastic
cable ties or a pair of tensioning straps - T10038- are therefore
very good for this.
If the subframe is removed now, the left drive shaft may be re‐
satelettronica
moved.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se
Next remove -subframe- together
tho with -pendulum support- and tee
or
au -steering-.
-both suspension links-ssand ac
ce
e
pt
du
an
y li
ab
ility
h re
hole
If the position of the subframe was not fixed, the wheels must now
spec
be aligned.
es, in part or in w
t to the co
Once the subframe has been removed, the engine and gearbox
m
at
must be supported.
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– A small cover plate is located above the right drive shaft flange
on the intermediate plate for engine and gearbox. Remove
cover plate -A-.
– Set up gearbox support - 3282- with adjustment plate -
3282/42 A- .
– Move engine and gearbox jack - V.A.G 1383 A- under gearbox
and support gearbox. Do not raise.
The gearbox is separated from the engine in this position.
– Remove remaining engine/gearbox connecting bolts.
– Press gearbox off engine while »observing selector lever ca‐
ble«, and lower gearbox.
Transporting gearbox and securing to assembly stand
⇒ page 283 .
Install gearbox ⇒ page 273 .
satelettronica
Brief description . Volkswagen AG
gen AG does
swa
The gearbox yisV removed downwards separately.
olk not
gu »From above«
edb ara
nte
The battery,
horis
air filter and starter are removed. The coolant
eo hoses
ut clamped off. Left subframe mounting is removed
musts abe r a and
c
engine and gearbox supported.
s
ce
le
un
pt
»From below«
an
d
itte
y li
rm
ab
ility
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
tion in
thi
en
t.
yi Co
removed. t. Cop py
rig
gh ht
In any case, locating pins - T10096- are necessary.
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
If the position of the -subframe- is not fixed with the pins, the
wheels must later be aligned.
In this case, wheel alignment would be unnecessary and costly
additional work! Save yourself this work and your customer the
expense!
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
♦ Support - 10-222A-
r
rp
cu
o
m
f
en
ng
♦ Adapter - 10-222A/3-
t.
yi Co
Cop py
♦ Additional hook - 10-222A/13-
t. rig
gh ht
pyri by
Vo
o
♦ Gearbox support - 3282- by c lksw
cted agen
Prote AG.
♦ Adjustment plate - 3282/42 A-
♦ Insert tool, 18 mm - T10179-
ce
le
pt
an
d
itte
y li
rm
ab
pe
ility
Note
ot
wit
, is n
h re
After loosening centre bolt, do not lower vehicle to ground again.
hole
spec
satelettronica
es, in part or in w
t to the co
– Depress brake pedal to remove bolt for left drive shaft
-arrow- (2nd mechanic).
– Remove complete air filter housing ⇒ Rep. gr. 24 ; Removing
rrectness of i
and installing air filter .
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
satelettronica
Both securing clips must be later renewed when cable is adjusted.
Remove cable with great care from cable support bracket on
gearbox. Do not bend it. agen
AG. Volkswagen AG d
oes
olksw not
Cable may also be pushed slightly backwards out of cable support
d by
V gu
ara
bracket and removed later when gearbox is lowered. But oris then
e nte
eo
observe cable when lowering gearbox. aut
h
ra
s s c
During later installation, do not clip »small« securing clips on until
ce
le
un
pt
cable has been checked and adjusted ⇒ page 70 .
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Clamp off coolant hoses using hose clamps to 40 mm - 3093-
es, in part or in w
connector.
– Remove all upper engine/gearbox connecting bolts.
nform
ercia
a
com
ti
One bolt is located in hole for starter at the height of the solenoid.
on in
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
satelettronica
l purpos
nf
ercia
orm
m
atio
om
n in
c
thi
te
sd
iva
cu
o
m
f
This wiring harness will later be removed together with the sub‐
en
ng
t.
yi
frame. This will save time-consuming work on the steering and
Co
Cop py
heat shield.
t. rig
gh ht
pyri by
Vo
o
– Remove all upper engine/gearbox connecting bolts. Insert
c by lksw
cted agen
18 mm - T10179- is especially good for this purpose.
Prote AG.
satelettronica
– Then lower engine and gearbox slightly using spindles of sup‐
port bracket - 10 - 222 A- so that bracket can be removed.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
At most, 4 turns are sufficient to remove bracket -arrow-. ss
ce
e
nl
pt
du
an
itte
y li
housing liner ⇒ General body repairs, exterior; Rep. gr. 66 ;
erm
ab
Removing and installing wheel housing liners; Front wheel
ility
ot p
housing liners .
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– If fitted, remove the heat shield over the right-hand drive shaft.
Tightening torque ⇒ Rep. gr. 40 ; Repairing drive shafts
nform
ercia
at
om
ion
in t
or
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
– A small cover plate is located above the right drive shaft flange
y li
erm
ab
h re
3282/42 A- .
spec
es, in part or in w
t to the co
orm
atio
m
⇒ page 283 .
o
n in
or c
sd
iva
o
r
rp
cu
m
f
en
ng
t.
yi
3.2 and 3.6 l - V6 engine
Co
Cop py
t. rig
gh ht
yri
Brief description
p by
o Vo
by c lksw
cted agen
The gearbox is removed downwards separately. »From above«
Prote AG.
The battery, air filter and starter are removed. The coolant hoses
must be clamped off. Left subframe mounting is removed and AG. Volkswagen AG d
engine and gearbox supported. lksw
agen oes
n o ot g
yV ua
»From below« ir se
db ran
tee
ho
Remove -subframe- together with -pendulum support-,aut or
ac
ss
-steering rack- and -both suspension links-.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
For information on how to remove the -subframe-, refer to ⇒ Rep.
ss
gr. 40 . If the job is done correctly, the subframe can be removed
o
cial p
f i
and reinstalled without subsequently causing increased tyre
nform
wear, which may lead to customer complaints. It is recommended
satelettronica
mer
atio
m
n
c
i
or
n
removed.
thi
te
sd
va
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
If the position of the -subframe- is not fixed with the pins, the
wheels must later be aligned.
In this case, wheel alignment would be unnecessary and costly
additional work! Save yourself this work and your customer the
expense!
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
satelettronica
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Support - 10-222A-
♦ Adapter - 10-222A/18-
♦ Adapter - 10-222A/8-
♦ Gearbox support - 3282-
♦ Adjustment plate - 3282/42 A-
♦ Insert tool, 18 mm - T10179-
Special tools and workshop equipment required
♦ Bracket - T10338-
ce
e
nl
pt
du
– Remove both front wheels.
an
itte
y li
erm
ab
Unlike most other vehicles, in this case the left drive shaft does
ility
ot p
wit
, is n
h re
hole
spec
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
es, in part or in w
t to the co
– Remove complete air filter housing ⇒ Rep. gr. 24 ; Removing
and installing air filter .
rrectness of i
– Unbolt bracket beneath air filter from longitudinal carrier (3
satelettronica
l purpos
bolts).
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Removing
nform
ercia
at
om
ion
c
in t
or
his
e
do
riv
cum
housing liners .
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
satelettronica
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Disconnect -wiring harness- coming »from below« from sub‐
frame.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
– Disconnect wire -1- from electronics box. Cop
yi Co
py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
satelettronica
ce
le
un
pt
It is advisable to now do all the work which must be done »be‐
an
d
itte
y li
neath« the car. This will avoid having the weight of the engine
erm
ab
carried by the support bar and, consequently, by the body, for »a
ility
ot p
long time«.
wit
is n
h re
ole,
– If fitted, remove the heat shield over the right-hand drive shaft.
spec
urposes, in part or in wh
t to the co
– Unbolt drive shafts from gearbox and carefully lay to side.
The surface protection of the shafts must not be damaged. Plastic
rrectne
cable ties or a pair of tensioning straps - T10038- are therefore
very good for this.
ss
– Remove secondary air pump motor - V101- with bracket from
o
cial p
f i
front of engine and lay to side.
nform
mer
atio
om
n
– Remove coupling rods from suspension links.
c
i
or
n thi
te
o
pr
cum
r
en
ng
t.
yi Co
op py
Next remove -subframe- together with -pendulum support- and
t. C rig
gh ht
yri
-both suspension links- and -steering-. p by
co Vo
by lksw
cted agen
For information on how to remove the -subframe-, refer to ⇒ Rep. Prote AG.
gr. 40 . If the job is done correctly, the subframe can be removed
and reinstalled without subsequently causing increased tyre
wear, which may lead to customer complaints. It is recommended
to read this information »before« removing gearbox. Then the
position of the -subframe- can be properly fixed and the subframe
removed.
If the position of the subframe was not fixed, the wheels must now
be aligned.
⇒ Running gear, axles, steering; Rep. gr. 40 ; Locating subframe
and brackets .
When removing subframe, please remember:
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
satelettronica
the spacer tube - 10 - 222 A /17- to the rear.
rm
m
atio
m
n in
or c
thi
♦ Adapter - 10 - 222 A /18-
te
sd
iva
o
r
rp
cu
♦ Adapter - 10 - 222 A /8- »smooth side« to engine compartment
o
m
f
en
ng
t.
♦ Holder - T10338-
yi Co
Cop py
t. rig
♦ Use spacer tube - 10 - 222 A /17- on the »rear« spindle
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
e
nl
Install gearbox ⇒ page 273 .
pt
du
an
itte
y li
erm
ab
10.12 Removing gearbox, Golf 2004 ► with
ility
ot p
wit
, is n
h re
hole
spec
Brief description
es, in part or in w
satelettronica
t to the co
The gearbox is removed downwards separately. »From above«
The battery, air filter and starter are removed. The coolant hoses
must be clamped off. Left subframe mounting is removed and
rrectness of i
engine and gearbox supported.
l purpos
»From below«
Remove -subframe- together with -pendulum support-,
nf
ercia
o
-steering rack- and -both suspension links-.
rm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
If the position of the -subframe- is not fixed with the pins, the
wheels must later be aligned.
In this case, wheel alignment would be unnecessary and costly
additional work! Save yourself this work and your customer the
expense!
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
♦ Support - 10-222A-
do
priv
cum
or
♦ Adapter - 10-222A/3-
f
en
ng
t.
yi Co
op
♦ Additional hook - 10-222A/13- C py
ht. rig
rig ht
py by
♦ Gearbox support - 3282- co Vo
by lksw
cted agen
Prote
♦ Adjustment plate - 3282/42 A-
AG.
ce
le
pt
an
d
itte
y li
Removing:
erm
ab
ility
ot p
wit
height.
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
and installing air filter .
satelettronica
– Remove battery and -battery box- ⇒ Rep. gr. 27 ; Battery;
rrectne
Removing and installing battery .
– Remove engine cover panel.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
Both securing clips must be later renewed when cable
thor is adjusted. eo
au ra
c
Remove cable with great care from cable support
ss
bracket on
ce
gearbox. Do not bend it. le
un
pt
an
d
itte
y li
Cable may also be pushed slightly backwards out of cable support
rm
ab
bracket and removed later when gearbox is lowered. But then
pe
ility
observe cable when lowering gearbox.
ot
wit
, is n
h re
During later installation, do not clip »small« securing clips on until
hole
satelettronica
spec
cable has been checked and adjusted ⇒ page 70 .
es, in part or in w
t to the co
rrectness of i
– Clamp off coolant hoses using hose clamps to 40 mm - 3093-
l purpos
nform
ercia
nuts M6).
m
a
– Release mechatronic unit connector by turning and pull off
com
tion in
connector.
r
te o
thi
s
– Now remove all upper connecting bolts between gearbox and
iva
do
r
engine.
rp
cum
fo
en
ng
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Disconnect earth cable -2-.
– Disconnect electrical connector -3-.
rrectness of i
This wiring harness will later be removed together with the sub‐
l purpos
nf
ercia
or
eyes, remove them now.
satelettronica
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi
– Now separate steering from steering column.
Co
Cop py
t. rig
gh ht
Refer to ⇒ Running gear, axles, steering; Rep. gr. 48 ; Removing yri
p by
o Vo
and installing steering rack to see what must be done.
c by lksw
cted agen
Prote AG.
In any case, first return the steering wheel to the straight-ahead
position. Engage steering wheel lock. Notes on tightening the bolt
can also be found in these instructions.
– Separate steering box from steering column.
– Remove filler pieces from upper edges of both wings
ce
e
nl
pt
du
an
itte
y li
satelettronica
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
at
om
ion
c
If the position of the subframe was not fixed, the wheels must now
in t
or
be aligned.
his
ate
do
riv
cum
or
and brackets .
f
en
ng
t.
yi Co
op
When removing subframe, please remember:
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– If fitted, remove the heat shield over the right-hand drive shaft.
satelettronica
Tightening torque ⇒ Rep. gr. 40 ; Repairing drive shafts
l purpos
nform
ercia
a
com
t
very good for this.
ion in
r
te o
The air pipe and the electric coolant pump in front of the gearbox
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op
This is sufficient and creates space to support the gearbox. The C py
t. rig
coolant circuit and charge air pipe do not need to opened or sep‐
gh ht
pyri by
arated, respectively.
co Vo
by lksw
cted agen
Prote AG.
– Set up gearbox support - 3282- with adjustment plate -
3282/42 A- .
ce
le
un
pt
10.13 Removing gearbox, Golf 2004 ► with
an
d
itte
y li
2.0 l petrol engine
erm
ab
ility
ot p
wit
Brief description
is n
h re
ole,
spec
urposes, in part or in wh
The battery, air filter and starter are removed. The coolant hoses
t to the co
must be clamped off. Left subframe mounting is removed and
satelettronica
engine and gearbox supported.
rrectne
»From below«
Remove -subframe- together with -pendulum support-,
ss
-steering rack- and -both suspension links-.
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
For information on how to remove the -subframe-, refer to ⇒ Rep.
gr. 40 . If the job is done correctly, the subframe can be removed
and reinstalled without subsequently causing increased tyre
wear, which may lead to customer complaints. It is recommended
to read this information »before« removing gearbox. Then the
position of the -subframe- can be properly fixed and the subframe
removed.
In any case, locating pins - T10096- are necessary.
If the position of the -subframe- is not fixed with the pins, the
wheels must later be aligned.
In this case, wheel alignment would be unnecessary and costly
additional work! Save yourself this work and your customer the
expense!
AG. Volkswagen AG d
agen oes
olksw not
y V gu
b
satelettronica
d ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Support - 10-222A-
♦ Adapter - 10-222A/3-
♦ Additional hook - 10-222A/13-
♦ Gearbox support - 3282-
♦ Adjustment plate - 3282/42 A-
♦ Insert tool, 18 mm - T10179-
Note
satelettronica
-arrow- (second mechanic required).
– Remove complete air filter housing ⇒ Rep. gr. 24 ; Removing
and installing air filter . gen AG
. Volkswagen AG
d a oes
ksw not
Vol gu
d by ara
e nte
ris
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
spec
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
satelettronica
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
Both securing clips must be later renewed when cable is adjusted.
ot
wit
, is n
h re
Remove cable with great care from cable support bracket on
hole
spec
gearbox. Do not bend it.
es, in part or in w
t to the co
Cable may also be pushed slightly backwards out of cable support
bracket and removed later when gearbox is lowered. But then
observe cable when lowering gearbox.
rrectness of i
During later installation, do not clip »small« securing clips on until
cable has been checked and adjusted ⇒ page 70 .
l purpos
nform
mercia
a
com
tion in
do
cum
fo
nuts M6).
en
ng
t.
yi Co
op
– Release mechatronic unit connector by turning and pull off C py
t. rig
connector.
gh ht
pyri by
Vo
o
by c lksw
– Now remove all upper connecting bolts between gearbox and cted agen
Prote AG.
engine. Insert 18 mm - T10179- is especially good for this pur‐
pose.
– Remove filler pieces from upper edges of both wings
– If there are hoses and cable connections in area of engine
support eyes for support bracket - 10-222A- , remove these
now.
AG. Volkswagen AG d
agen oes
satelettronica
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
– Remove noise insulation and lower part of front left wheel
ot p
wit
housing liner ⇒ General body repairs, exterior; Rep. gr. 66 ;
, is n
h re
Removing and installing wheel housing liners; Front wheel
hole
spec
housing liners .
es, in part or in w
t to the co
– Unbolt drive shafts from gearbox and carefully lay to side.
The surface protection of the shafts must not be damaged. Plastic
cable ties or a pair of tensioning straps - T10038- are therefore
rrectness of i
very good for this.
l purpos
If the subframe is removed now, the left drive shaft may be re‐
moved.
nform
ercia
at
om
ion
in t
or
t.
yi Co
position of the -subframe- can be properly fixed and the subframe Cop py
removed.
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– A small cover plate is located above the right drive shaft flange
on the intermediate plate for engine and gearbox. Remove
cover plate -A-.
– Set up gearbox support - 3282- with adjustment plate -
3282/42 A- .
– Move engine and gearbox jack - V.A.G 1383 A- under gearbox
and support gearbox. Do not raise.
The gearbox is separated from the engine in this position.
– Remove remaining engine/gearbox connecting bolts.
– Press gearbox off engine while »observing selector lever ca‐
ble«, and lower gearbox.
Transporting gearbox and securing to assembly stand
⇒ page 283 .
Install gearbox ⇒ page 273 .
satelettronica
Brief description
The gearbox is removed downwards separately. »Fromenabove«
AG. Volkswagen AG
ag does
ol ksw not
The air filter and starter are removed. Wiring harness
yV which gu
db ara
comes from »beneath« from subframe must rise be disconnected so nte
that subframe can later be removed. The u thocoolant hoses must be eo
ra
clamped off. Left subframe mounting siss a removed and engine and c
gearbox supported.
ce
e
nl
pt
du
an
itte
»From below«
y li
erm
ab
Remove -subframe- together with -pendulum support- and
ility
ot p
h re
hole
removed.
l purpos
If the position of the subframe was not fixed, the wheels must now
be aligned.
nform
ercia
After the subframe has been removed, the engine and gearbox
m
io
arated. Then the »last« connecting bolt between the engine and
n
c
in t
r
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
c
satelettronica
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
io
in t
r
clamps to 25 mm - 3094- .
o
his
ate
do
riv
cum
for
en
g
t.
yi Co
op py
♦ Locating pins - T10096-
t. C rig
gh ht
pyri by
Vo
o
♦ Support bar - 10 - 222 A- with hook - 10 - 222 A /10-
c by lksw
cted agen
Prote AG.
♦ Adapter - 10 - 222 A /18-
Special tools and workshop equipment required
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
♦ Bracket - T10338-
l purpos
nform
mercia
a
com
tion in
r
te o
thi
satelettronica
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote
♦ Adjustment plate - 3282/42 A-
AG.
Removing:
– Raise vehicle. All 4 supports of lifting platform must be at same
height.
– Move selector lever to position »P«.
– Disconnect battery ⇒ Rep. gr. 27 ; Battery; Disconnecting and
connecting battery .
Note
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
– Remove starter
aut ⇒ Electrical system; Rep. gr. 27 ; Removing ra
c
and installing
ss
starter
ce
e
nl
satelettronica
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
could be damaged.
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
– Clamp off coolant hoses using hose clamps to 40 mm - 3093-
itte
y li
or hose clamps to 25 mm - 3094- and remove.
rm
ab
pe
ility
– Release mechatronic unit connector by turning and pull off
ot
wit
, is n
connector.
h re
hole
spec
– Unbolt wiring retainer from front of »black« gearbox cover (2
es, in part or in w
nuts M6).
t to the co
rrectness of i
l purpos
nform
ercia
frame.
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t.
satelettronica
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
and installing steering rack to see what must be done.
un
pt
an
d
itte
y li
erm
ab
position. Engage steering wheel lock. Notes on tightening the bolt
ility
ot p
wit
is n
h re
– Now remove all upper connecting bolts between gearbox and
ole,
spec
engine. Insert 18 mm - T10179- is especially good for this pur‐
urposes, in part or in wh
pose.
t to the co
It is advisable to now do all the work which must be done »be‐
neath« the car. This will avoid having the weight of the engine
rrectne
carried by the support bar and, consequently, by the body, for »a
long time«.
s
– Remove noise insulation and lower part of front left wheel
s o
cial p
f in
Removing and installing wheel housing liners; Front wheel
form
mer
housing liners .
atio
om
n
c
i
or
n
Next remove -subframe- together with -pendulum support- and
thi
e
sd
a
satelettronica
iv
o
pr
cum
For information on how to remove the -subframe-, refer to ⇒ Rep.
r
fo
en
ng
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
Before removing hor bolts -2- through -5- on both sides, have locating
eo
satelettronica
ut
pins - T10096-
ss a at hand and support subframe with engine and
ra
c
gearbox support - V.A.G 1383 A- .
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
sides.
As soon as bolt -2- has been removed, immediately insert a lo‐
nform
ercia
at
ion
c
in t
r
If the position of the subframe was not fixed, the wheels must now
o
his
te
be aligned.
a
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
– Carefully lower subframe, observing wiring harness to engine
itte
y li
erm
compartment.
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
cum
or
satelettronica
f
en
ng
satelettronica
– If necessary, remove bracket with secondary pump and lay to
side with pump.
– Remove all connecting bolts but one between engine and
AG. Volkswagen AG d
gearbox. lkswagen oes
n o ot g
yV ua
It is advisable to leaveriandb
se easily accessible bolt installed. ran
tee
tho or
– Remove filler pieces
sa
u from upper edges of both wings ac
s
ce
e
pt
du
y li
now.
erm
ab
ility
ot p
wit
, is n
spec
es, in part or in w
nf
ercia
orm
m
atio
om
n in
or c
thi
sd
iva
o
r
cu
o
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
satelettronica
with 1.9 l and 2.0 l diesel engine, with 2.0
l petrol engine
Brief description
The gearbox is removed downwards separately. »From above«
The battery, air filter and starter are removed. The coolant hoses
must be clamped off. Left subframe mounting is removed, engine
and gearbox supported.
»From below« agen
AG. Volkswagen AG d
oes
olksw not
Remove -subframe- by V together with -pendulum support-, gu
ara
ed
-steering rack-
horis and -both suspension links-. nte
eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
removed.
a
com
tion in
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
If the position of the -subframe- is not fixed with the pins, the
wheels must later be aligned.
In this case, wheel alignment would be unnecessary and costly
additional work! Save yourself this work and your customer the
expense!
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
Special tools and workshop
pe
ility
equipment required
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Support - 10-222A-
♦ Adapter - 10-222A/3-
♦ Adapter - 10-222A/8-
♦ Gearbox support - 3282-
♦ Adjustment plate - 3282/42 A-
♦ Insert tool, 18 mm - T10179-
ce
e
nl
pt
du
an
♦ Tools without illustration:
itte
y li
erm
ab
♦ Wing supports - T10311-
ility
ot p
wit
, is n
♦ Pin - 3282/29-
h re
hole
♦ Support - 3282/59-
spec
es, in part or in w
t to the co
♦ If no hose clamps to 40 mm - 3093- are available, use hose
clamps to 25 mm - 3094- .
♦ Engine and gearbox jack - V.A.G 1383 A-
rrectness of i
Removing:
l purpos
nform
ercia
at
om
ion
c
in t
or
his
e
Note
at
do
priv
cum
or
en
g
satelettronica
n
t.
yi Co
Cop py
– Depress brake pedal to remove bolt for left drive shaft
t. rig
gh ht
yri
-arrow- (2nd mechanic).
p by
o Vo
by c lksw
cted agen
– Remove complete air filter housing ⇒ Rep. gr. 24 ; Removing
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
– Remove selector lever cable from gearbox.
an
d
itte
y li
rm
ab
Use pliers to remove the washer on the cable support bracket. Do
pe
ility
not use a sharp-edged lever, as the rubber grommet on the cable
ot
wit
could be damaged.
, is n
h re
hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos
nform
ercia
a
Remove cable with great care from cable support bracket on
com
tio
gearbox. Do not bend it.
n in
r
te o
thi
Cable may also be pushed slightly backwards out of cable support
s
iva
do
bracket and removed later when gearbox is lowered. But then
r
rp
cum
fo
en
ng
t.
yi Co
op
During later installation, do not clip »small« securing clips on until C py
t. rig
cable has been checked and adjusted ⇒ page 70 . gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
satelettronica
♦ Rack feet - 10 - 222 A /1-
. Volkswagen AG
♦ Adapter - 10 - 222 A /3-kswagen AG does
not
Vol gu
♦ Adapter - 10 - 222 by
ed A /8- ara
ris nte
ho eo
♦ Adapter - 10aut- 222 A /16- ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
at
ion
c
in t
r
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2 l - TDI engine
– Support engine and gearbox. Do not raise.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
2 l - FSI engine
satelettronica
– Support engine and gearbox. Do not raise.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– If fitted, remove the heat shield over the right-hand drive shaft.
Tightening torque ⇒ Rep. gr. 40 ; Repairing drive shafts
– Unbolt drive shafts from gearbox and carefully lay to side.
The surface protection of the shafts must not be damaged. Plastic
cable ties or a pair of tensioning straps - T10038- are therefore
very good for this.
If the subframe is removed now, the left drive shaft may be re‐
moved.
. Volkswagen AG
gen AG does
Next remove -subframe- together with -pendulum
Vol
ksw
a
support- and not
-both suspension links- and -steering-.
ed by gu
ara
ris nte
o eo
For information on how to remove aut the -subframe-, refer to ⇒ Rep.
h
ra
gr. 40 . If the job is done correctly,
ss the subframe can be removed c
ce
and reinstalled without subsequently causing increased tyre
le
un
pt
wear, which may lead to customer complaints. It is recommended
an
d
itte
y li
to read this information »before« removing gearbox. Then the
rm
ab
position of the -subframe- can be properly fixed and the subframe
pe
ility
satelettronica
ot
removed.
wit
, is n
h re
If the position of the subframe was not fixed, the wheels must now
hole
spec
be aligned.
es, in part or in w
t to the co
⇒ Running gear, axles, steering; Rep. gr. 40 ; Locating subframe
and brackets .
rrectness of i
When removing subframe, please remember:
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– A small cover plate is located above the right drive shaft flange
on the intermediate plate for engine and gearbox. Remove this
cover plate -A-.
– Set up gearbox support - 3282- with adjustment plate -
3282/42 A- .
– Move engine and gearbox jack - V.A.G 1383 A- under gearbox
and support gearbox. Do not raise.
The gearbox is separated from the engine in this position.
– Remove remaining engine/gearbox connecting bolts.
– Press gearbox off engine while »observing selector lever ca‐
ble«, and lower gearbox.
Transporting gearbox and securing to assembly standgen AG
. Volkswagen AG
does
swa
⇒ page 283 . yV
olk not
gu b ara
ed nte
Install gearbox ⇒ page 273 . thoris e or
au ac
ss
10.16 Removing gearbox, Eos 2006 ► with 2.0
ce
le
un
pt
an
d
l petrol engine
itte
y li
rm
ab
satelettronica
pe
ility
Brief description
ot
wit
, is n
h re
hole
spec
The battery, air filter and starter are removed. The coolant hoses
es, in part or in w
t to the co
subframe mounting is unbolted.
»From below«
rrectness of i
Remove -subframe- together with -pendulum support-,
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
For information on how to remove the -subframe-, refer to ⇒ Rep. Prote AG.
gr. 40 . If the job is done correctly, the subframe can be removed
and reinstalled without subsequently causing increased tyre
wear, which may lead to customer complaints. It is recommended
to read this information »before« removing gearbox. Then the
position of the -subframe- can be properly fixed and the subframe
removed.
In any case, locating pins - T10096- are necessary.
If the position of the -subframe- is not fixed with the pins, the
wheels must later be aligned.
In this case, wheel alignment would be unnecessary and costly
additional work! Save yourself this work and your customer the
expense!
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Support - 10-222A-
♦ Adapter - 10-222A/3-
♦ Adapter - 10-222A/8-
♦ Gearbox support - 3282-
♦ Adjustment plate - 3282/42 A-
♦ Insert tool, 18 mm - T10179-
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
Special tools and workshop equipment required
hole
spec
es, in part or in w
t to the co
♦ If no hose clamps to 40 mm - 3093- are available, use hose
clamps to 25 mm - 3094- .
rrectness of i
♦ Engine and gearbox jack - V.A.G 1383 A-
satelettronica
l purpos
Removing:
– Raise vehicle. All 4 supports of lifting platform must be at same
nf
ercia
o
height.
rm
m
atio
m
n in
or c
thi
te
sd
iva
Note
o
r
rp
cu
o
m
f
en
ng
t.
After loosening centre bolt, do not lower vehicle to ground again.
yi Co
Cop py
t. rig
gh ht
yri by
– Depress brake pedal to remove bolt for left drive shaft cop Vo
by lksw
-arrow- (2nd mechanic). cted agen
Prote AG.
satelettronica
and installing starter
It is advisable to remove the »lower« bolt first.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
– Remove
s au selector lever cable from gearbox. ra
c
s
ce
pt
du
y li
could be damaged.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
atio
n in
sd
iva
o
r
cu
o
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
satelettronica
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Disconnect wire -1- from electronics box.
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
en
ng
t.
yi
– Disconnect electrical connector -3-.
Co
Cop py
t. rig
This wiring harness will later be removed together with the sub‐
gh ht
pyri by
frame. This will save time-consuming work on the steering and
o Vo
by c lksw
cted
heat shield.
agen
Prote AG.
ce
le
un
pt
an
– Separate steering box from steering column.
d
itte
y li
erm
ab
It is advisable to now do all the work which must be done »be‐
ility
ot p
neath« the car. This will avoid having the weight of the engine
wit
is n
h re
ole,
long time«.
spec
urposes, in part or in wh
t to the co
housing liner ⇒ General body repairs, exterior; Rep. gr. 66 ;
Removing and installing wheel housing liners; Front wheel
housing liners .
rrectne
– If fitted, remove the heat shield over the right-hand drive shaft.
ss
Tightening torque ⇒ Rep. gr. 40 ; Repairing drive shafts
o
cial p
f in
– Unbolt drive shafts from gearbox and carefully lay to side.
form
mer
satelettronica
The surface protection of the shafts must not be damaged. Plastic
atio
m
n
c
i
or
n
very good for this.
thi
te
sd
va
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Next remove -subframe- together with -pendulum support- and
-both suspension links- and -steering-.
For information on how to remove the -subframe-, refer to ⇒ Rep.
gr. 40 . If the job is done correctly, the subframe can be removed
and reinstalled without subsequently causing increased tyre
wear, which may lead to customer complaints. It is recommended
to read this information »before« removing gearbox. Then the
position of the -subframe- can be properly fixed and the subframe
removed.
If the position of the subframe was not fixed, the wheels must now
be aligned.
⇒ Running gear, axles, steering; Rep. gr. 40 ; Locating subframe
and brackets .
When removing subframe, please remember:
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
satelettronica
hole
spec
(At rearmost of the 3 support points of the battery tray)
es, in part or in w
t to the co
2 l - FSI turbocharged engine
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
e
do
priv
c
♦ Support bracket - 10 - 222 A-
um
for
en
ng
t.
♦ Adapter - 10 - 222 A /3-
yi Co
Cop py
ht. rig
♦ Adapter - 10 - 222 A /8- »smooth side« to engine compartment rig ht
py by
co Vo
by lksw
♦ Holder - T10346- cted agen
Prote AG.
ce
e
nl
pt
ble«, and lower gearbox.
du
an
itte
y li
Transporting gearbox and securing to assembly stand
erm
ab
ility
⇒ page 283 .
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
l diesel engine
rrectness of i
Brief description
satelettronica
l purpos
nf
ercia
or
subframe mounting is unbolted.
m
m
atio
m
»From below«
o
n in
or c
thi
e
sd
iva
cu
o
m
f
t.
yi Co
gr. 40 . If the job is done correctly, the subframe can be removed Cop py
and reinstalled without subsequently causing increased tyre
t. rig
gh ht
yri
wear, which may lead to customer complaints. It is recommended
p by
o Vo
by c lksw
to read this information »before« removing gearbox. Then the Prote
cted AG.
agen
position of the -subframe- can be properly fixed and the subframe
removed.
If the position of the -subframe- is not fixed with the pins, the
wheels must later be aligned.
In this case, wheel alignment would be unnecessary and costly
additional work! Save yourself this work and your customer the
expense!
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Support - 10-222A-
♦ Adapter - 10-222A/8-
♦ Additional hook - 10-222A/13-
♦ Gearbox support - 3282-
♦ Adjustment plate - 3282/42 A-
♦ Insert tool, 18 mm - T10179-
Special tools and workshop equipment required
♦ In any case, locating pins - T10096- are necessary.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
♦ or bit - T10099/1-
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
satelettronica
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Pin - 3282/29-
Removing:
– Raise vehicle. All 4 supports of lifting platform must be at same
height.
– Move selector lever to position »P«.
– Remove both front wheels.
– Remove complete air filter housing ⇒ Rep. gr. 24 ; Removing
and installing air filter .
– Also remove charge air pipe -A- from turbocharger ⇒ Rep. gr.
21 ; Charge air system with turbocharger .
This will provide access to the rear engine support eye. n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
satelettronica
, is n
h re
hole
spec
Removing and installing battery .
es, in part or in w
t to the co
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Removing
and installing starter
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
satelettronica
engine. Insert 18 mm - T10179- is especially good for this pur‐
pose.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
– Separate steering box from steering column.
itte
y li
satelettronica
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
– Remove all bolts -1- and -2- for bracket -A-.
yi Co
Cop py
t. rig
– Then lower engine and gearbox slightly using spindles of sup‐
gh ht
yri by
port bracket - 10 - 222 A- so that bracket can be removed.
op Vo
by c lksw
cted agen
Prote AG.
– If fitted, remove the heat shield over the right-hand drive shaft.
Tightening torque ⇒ Rep. gr. 40 ; Repairing drive shafts
n AG. Volkswagen AG do
wage es n
satelettronica
olks ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
– Unbolt suspension links from suspension struts on both sides.
erm
ab
ility
ot p
wit
, is n
h re
The surface protection of the shafts must not be damaged. Plastic
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
The tensioning straps - T10038- are also very good for securing
m
atio
m
n in
or c
The left drive shaft can be set aside in the wheel housing.
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
removed as shown in this figure.
un
pt
an
d
itte
y li
If the position of the subframe was not fixed, the wheels must now
rm
ab
be aligned. pe
ility
ot
wit
⇒ Running gear, axles, steering; Rep. gr. 40 ; Locating subframe
, is n
h re
and brackets .
hole
spec
When removing subframe, please remember:
es, in part or in w
t to the co
– After removing a bolt -1-, immediately screw in a locating pin
- T10096- -2-.
rrectness of i
Once the subframe has been removed, the engine and gearbox
l purpos
must be supported.
nform
ercia
satelettronica
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– A small cover plate is located above the right drive shaft flange
on the intermediate plate for engine and gearbox. Remove this
cover plate -A-.
– Set up gearbox support - 3282- with adjustment plate -
3282/42 A- .
– Move engine and gearbox jack - V.A.G 1383 A- under gearbox
and support gearbox. Do not raise.
The gearbox is separated from the engine in this position.
– Remove remaining engine/gearbox connecting bolts.
– Press gearbox off engine while »observing selector lever ca‐
ble«, and lower gearbox.
Transporting gearbox and securing to assembly stand
⇒ page 283 .
Install gearbox ⇒ page 273 .
»From below«
Remove -subframe- together with -pendulum support-,
-steering rack- and -both suspension links-.
Left drive shaft is removed. Right drive shaft is only removed from
gearbox, but remains in vehicle.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
♦ Support - 10-222A-
t. rig
gh ht
pyri by
Vo
co
♦ Additional hook - 10-222A/2-
by lksw
cted agen
Prote AG.
♦ Adapter - 10-222A/3-
♦ Gearbox support - 3282-
♦ Adapter - 10-222A/16-
♦ Support - 3282/59-
AG. Volkswagen AG d
agen
satelettronica
oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
♦ Pin - 3282/48A-
a
com
tion in
♦ Pin - 3282/29-
r
te o
thi
s
iva
clamps to 25 mm - 3094- .
um
fo
en
ng
t.
yi
♦ Tools without illustration:
Co
Cop py
t. rig
♦ Engine and gearbox jack - V.A.G 1383 A-
gh ht
pyri by
Vo
co lksw
by
Support engine and gearbox in the Touran. cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
♦ To 11.06: small headlights -arrow 1-.
es, in part or in w
satelettronica
t to the co
♦ From 11.06 to 05.10: large headlights with curvature
-arrow 2-.
rrectness of i
♦ From 05.10: large headlights without curvature -arrow 3-
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
satelettronica
– Remove engine cover panel.
– Remove complete air filter housing ⇒ Rep. gr. 24 ; Removing
and installing air filter .
– Remove battery with battery tray ⇒ Rep. gr. 27 ; Battery;
Removing and installing battery .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
ab
pe
ility
Use pliers to remove the securing clip on the cable support brack‐
ot
wit
, is n
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
208
by lksw
cted agen
Rep. gr.34 - Controls, housing Prote AG.
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
6-speed dual clutch gearbox 02E - Edition 01.2018
satelettronica
Insert 18 mm - T10179- is especially good for this purpose.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
One bolt is located in hole for starter at the height of the solenoid.
an
d
itte
ab
pe
ility
wit
, is n
now.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
209
agen
Prote AG.
10. Removing and installing gearbox
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
6-speed dual clutch gearbox 02E - Edition 01.2018
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
– Now attach additional hook - 10-222A/2- to rear left of engine
erm
ab
satelettronica
-arrow-.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
at
om
in t
or
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se
– Secure right drive shaft tothosuspension strut with tensioning tee
or
strap - T10038- . au ac
ss
satelettronica
ce
e
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Only in some 1.4 l petrol engines:
l purpos
atio
forwards.
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
– Remove front exhaust pipe. In this way, lower engine/gearbox
Prote AG.
– A small cover plate is located above the right drive shaft flange
on the intermediate plate for engine and gearbox. Remove
cover plate -A-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
ut
satelettronica
a ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Then lower engine/gearbox slightly using spindles of support
es, in part or in w
t to the co
– Set up gearbox support - 3282- with adjustment plate -
3282/42 A- .
rrectness of i
– Move engine and gearbox jack - V.A.G 1383 A- under gearbox
l purpos
at
ble«, and lower gearbox.
om
ion
c
in t
r
his
ate
do
priv
en
ng
t.
2.0 l diesel engine
yi Co
Cop py
ht. rig
rig ht
Brief description py by
co Vo
by lksw
cted agen
The gearbox is removed downwards separately. »From above« Prote AG.
The battery, air filter and starter are removed. The coolant hoses
must be clamped off. Support engine and gearbox before left
subframe mounting is unbolted.
»From below«
Remove ⇒ pendulum support. The subframe remains in the ve‐
hicle.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
satelettronica
or eo
th
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
♦ Support - 10 - 222 A-
m
a
com
tio
♦ Adjustment plate - 3282/42 A-
n in
r
te o
do
r
rp
cum
en
g
clamps to 25 mm - 3094- .
n
t.
yi Co
Cop py
♦ Gearbox support - 3282-
t. rig
gh ht
pyri by
Vo
o
♦ Insert tool, 18 mm - T10179-
c by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
ksw not
Special tools and workshop equipment required by Vol
gu
ara
d
ise nte
♦ Tools without illustration: thor eo
au ra
s c
♦ Engine support - 3300 A- s
ce
e
nl
pt
du
♦ Pin - 3282/29-
an
itte
y li
erm
ab
♦ Adjustment plate - 3282/42 A-
ility
ot p
satelettronica
♦ If no hose clamps to 40 mm - 3093- are available, use hose
wit
, is n
h re
clamps to 25 mm - 3094- .
hole
spec
♦ Engine and gearbox jack - V.A.G 1383 A-
es, in part or in w
t to the co
Removing:
– Raise vehicle. All 4 supports of lifting platform must be at same
rrectness of i
height.
l purpos
nform
ercia
at
– Remove intake hose from turbocharger so that rear eye is ac‐
om
io
cessible for »hanging« engine.
n
c
in t
or
his
e
do
riv
cum
for
en
g
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Remove cable with great care from cable support bracket on
gearbox. Do not bend it.
Cable may also be pushed slightly backwards out of cable support
rrectness of i
bracket and removed later when gearbox is lowered. But then
observe cable when lowering gearbox.
l purpos
satelettronica
cable has been checked and adjusted ⇒ page 70 .
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
– Clamp off coolant hoses using hose clamps to 40 mm - 3093-
r
rp
cu
o
en
ng
t.
yi Co
op
– Release mechatronic unit connector by turning and pull off C py
t. rig
connector. gh ht
pyri by
Vo
co lksw
by
– Unbolt wiring retainer from front of »black« gearbox cover (2 Prote
cted AG.
agen
nuts M6).
– Now remove all upper connecting bolts between gearbox and
engine.
The following tools are appropriate for this:
♦ Socket insert - T10061-
♦ Socket insert - T10035-
♦ Insert tool 18 mm - T10179-
It is advisable to now do all the work which must be done »be‐
neath« the car. This will avoid having the weight of the engine
carried by the support bar and, consequently, by the body, for »a
long time«.
– Remove noise insulation and lower part of front left wheel
housing liner ⇒ General body repairs, exterior; Rep. gr. 66 ;
Removing and installing wheel housing liners; Front wheel
housing liners .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
s c
satelettronica
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Pull connector -1- off oil level and oil temperature sender -
hole
spec
G266- .
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
– Unscrew left transverse link from suspension strut.
erm
ab
ility
ot p
– Unbolt both drive shafts from gearbox and carefully lay to side.
wit
is n
h re
– Swing left drive shaft into wheel housing onto longitudinal
ole,
spec
member. This will keep the shaft out of the way during further
urposes, in part or in wh
work.
t to the co
The surface protection of the shafts must not be damaged. Plastic
cable ties or a pair of tensioning straps - T10038- are therefore
satelettronica
rrectne
very good for this.
ss o
cial p
f inform
mer
– If fitted, remove the heat shield over the right-hand drive shaft.
atio
m
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
– Remove ⇒ pendulum support, bolt -1-, -2- and bolt -3-.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
satelettronica
rrectness o
– Unbolt right securing bolt for heat shield -1- from subframe.
cial p
f inform
– Screw bracket - T10346- tight using a suitable bolt -2-.
mer
atio
m
Bolt -2- = M6 X 20
o
n
c
i
or
n thi
– Secure engine support - 3300 A- on bracket - T10346- .
te
sd
iva
o
r
Set engine support against engine crank case. Do not exert pres‐
p
cum
r
fo
sure yet! en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
satelettronica
– Remove lower starter bolt and remove starter.
It is easier to remove the starter »from above«. Lower vehicle.
There is now a working step »from above«. Volkswa
AG. gen AG
agen does
– Remove bolt in starter hole. y Volksw not
gu
b ara
ed nte
oris eo
th
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
– A small cover plate is located above the right drive shaft flange
spec
t to the co
3282/42 A- .
– Move engine and gearbox jack - V.A.G 1383 A- under gearbox
nform
ercia
at
om
in t
or
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
n AG. Volkswagen AG do
lkswage es n
Observe connecting bylines,
Vo hoses and radiator when moving
ot g
ua en‐
gine/gearbox assembly.
d ran
ir se tee
tho
or
au ac
ss
– Press gearbox off engine while »observing selector lever ca‐
ce
e
nl
pt
du
an
itte
y li
erm
ab
Transporting gearbox and securing to assembly stand
ility
ot p
⇒ page 283 .
wit
, is n
h re
Install gearbox ⇒ page 273 .
hole
spec
es, in part or in w
t to the co
2.0 l petrol engine
rrectness of i
Brief description
l purpos
satelettronica
The battery, air filter and starter are removed. The coolant hoses
nf
ercia
atio
om
n in
»From below«
or c
thi
te
o
r
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
ksw
satelettronica
ol not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
♦ Support - 10 - 222 A-
inform
mer
i
or
n thi
e
sd
va
clamps to 40 mm - 3093- .
i
o
pr
cum
r
fo
en
ng
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
Use pliers to remove the securing clip on the cable support brack‐
urposes, in part or in wh
t to the co
cable could be damaged.
rrectnes
satelettronica
s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e
sd
iva
o
pr
c
– Remove cable with great care from cable support bracket on
um
r
fo
en
ng
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
A bolt is located in the starter motor hole -arrow-. , is n
h re
hole
spec
– Remove noise insulation ⇒ General body repairs, exterior;
es, in part or in w
t to the co
sulation .
– Remove lower part of front left wheel housing liner ⇒ General
rrectness of i
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; Re‐
moving and installing wheel housing liner .
l purpos
satelettronica
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
a
nuts M6).
iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Pull connector -1- off oil level and oil temperature sender -
G266- .
satelettronica
db ara
ir se nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e
– Then lower engine/gearbox assembly horito
s dimension -a- using nte
eo
spindles of support bracket - 10 - s222
au A- .
t ra
c
s
Dimension -a- = approx. 50 mm
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
satelettronica
spec
urposes, in part or in wh
t to the co
rrectne
– Remove gearbox bracket -arrow-.
s
– Remove all connecting bolts except one which is in an easily
s o
cial p
f
accessible place between engine and gearbox.
inform
mer
atio
3282/42 A- .
om
n
c
i
or
n
– Move engine and gearbox jack - V.A.G 1383 A- under gearbox
thi
e
sd
iva
o
pr
cum
r
en
ng
t.
yi Co
– Remove last engine/gearbox connecting bolt. t. Cop py
rig
gh ht
– Press gearbox off engine while »observing selector lever ca‐ pyri by
Vo
o
by c
ble«, and lower gearbox.
lksw
cted agen
Prote AG.
Transporting gearbox and securing to assembly stand
⇒ page 283 .
Install gearbox ⇒ page 273 .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
satelettronica
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
c
♦ Support - 10 - 222 A- um
r
fo
en
ng
t.
yi
♦ Adjustment plate - 3282/42 A-
Co
Cop py
ht. rig
♦ Socket insert - T10061-
rig ht
py by
co Vo
by lksw
♦ If no hose clamps to 40 mm - 3093- are available, use hose
cted agen
Prote AG.
clamps to 25 mm - 3094- .
♦ Gearbox support - 3282-
♦ Insert tool, 18 mm - T10179-
Special tools and workshop equipment required
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
♦ Bracket - T10338-
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
satelettronica nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
♦ Without illustration
r
rp
cum
fo
en
g
t.
yi Co
Cop py
♦ Gearbox support - 3282-
t. rig
gh ht
pyri by
Vo
co
Removing:
by lksw
cted agen
Prote AG.
– Raise vehicle. All 4 supports of lifting platform must be at same
height.
– Move selector lever to position »P«.
– Disconnect battery ⇒ Rep. gr. 27 ; Battery; Disconnecting and
connecting battery .
– Remove complete air filter housing ⇒ Rep. gr. 24 ; Removing
and installing air filter , and remove retaining plate beneath
that.
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Removing
and installing starter
It is advisable to remove the »lower« bolt first.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
Both securing clips must be later renewed whenrise cable is adjusted.
d b ara
nte
tho eo
Remove cable with great care from cables a support bracket on
u ra
c
gearbox. Do not bend it. s
ce
e
nl
pt
du
an
itte
y li
bracket and removed later when gearbox is lowered. But then
erm
ab
observe cable when lowering gearbox.
ility
ot p
wit
, is n
satelettronica
h re
cable has been checked and adjusted ⇒ page 70 .
hole
spec
es, in part or in w
t to the co
rrectness of i
– Clamp off coolant hoses using hose clamps to 40 mm - 3093-
or hose clamps to 25 mm - 3094- and remove.
l purpos
nf
ercia
orm
– Unbolt wiring retainer from front of »black« gearbox cover (2
m
atio
m
nuts M6).
o
n in
or c
sd
a
engine.
iv
o
r
rp
cu
o
en
ng
t.
yi Co
op
♦ Socket insert - T10061- C py
t. rig
gh ht
yri by
♦ Socket insert - T10035- cop Vo
by lksw
cted agen
Prote
♦ Insert tool 18 mm - T10179-
AG.
satelettronica
– Therefore, clamp assembly tool - T10071- tight with a cloth.
This »protects« the ring.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove heat shield above right drive shaft -1- ⇒ Rep. gr. 40 ;
Heat shields for drive shafts .
l purpos
– Unbolt both drive shafts from gearbox and carefully lay to side.
nf
ercia
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
satelettronica
n AG. Volkswagen AG do
lkswage es n
– Remove counter-sunk bolt using insert - T10107 A- d b.
yV
o ot g
ua
ran
ir se tee
The flange shaft remains in the gearbox. utho
or
a ac
– Unbolt bevel box from gearbox and remove it. ss
ce
e
nl
pt
du
an
itte
y li
the bevel box is being removed.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Remove all connecting bolts but one between engine and
es, in part or in w
gearbox.
t to the co
It is advisable to leave an easily accessible bolt installed.
– Remove filler pieces from upper edges of both wings
rrectness of i
at
om
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
pt
satelettronica
du
an
and support gearbox. Do not raise.
itte
y li
erm
wit
, is n
t to the co
at
om
Brief description
ion
c
in t
or
cum
or
The battery, air filter and starter are removed. The coolant hoses
f
en
ng
t.
must be clamped off. Support engine and gearbox before left
yi Co
op
subframe mounting is unbolted.
C py
t. rig
gh ht
yri by
»From below« cop Vo
by lksw
cted agen
Prote AG.
Remove -subframe- together with -pendulum support-,
-steering rack- and -both suspension links-.
If the position of the -subframe- is not fixed with the pins, the
wheels must later be aligned.
In this case, wheel alignment would be unnecessary and costly
additional work! Save yourself this work and your customer the
expense!
It requires only a small effort to install the locating pins - T10096- .
Their benefit is enormous.
satelettronica
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
232
Prote AG.
Rep. gr.34 - Controls, housing
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
6-speed dual clutch gearbox 02E - Edition 01.2018
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Support - 10-222A-
♦ Adapter - 10-222A/3-
♦ Adapter - 10 - 222 A /18-
♦ Gearbox support - 3282-
♦ Adjustment plate - 3282/42 A-
♦ Insert tool, 18 mm - T10179-
Special tools and workshop equipment required
♦ Bracket - T10346-
ce
le
un
pt
an
d
itte
y li
rm
ab
satelettronica
pe
Removing:
ility
ot
wit
, is n
h re
hole
height.
spec
es, in part or in w
t to the co
– Remove both front wheels.
– Remove complete air filter housing ⇒ Rep. gr. 24 ; Removing
rrectness of i
and installing air filter .
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
– Remove selector lever cable from gearbox. d by V gu
ara
rise nte
Use pliers to remove the washer on the cableutsupport bracket. Do
ho eo
ra
not use a sharp-edged lever, as the rubberssgrommet
a
on the cable c
could be damaged.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
satelettronica
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Both securing clips must be later renewed when cable is adjusted.
rrectness of i
Remove cable with great care from cable support bracket on
l purpos
nf
ercia
o
bracket and removed later when gearbox is lowered. But then
rm
m
atio
observe cable when lowering gearbox.
om
n in
c
thi
e
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
– Clamp off coolant hoses using hose clamps to 40 mm - 3093- cop Vo
by lksw
or hose clamps to 25 mm - 3094- and remove.
cted agen
Prote AG.
satelettronica
– Disconnect earth cable -2-.
– Disconnect electrical connector -3-. AG. Volkswagen AG d
agen oes
ksw
This wiring harness will later be removed together bwithy V the sub‐
ol not
gu
frame. This way, you can avoid time-consuming risework
d on the ara
nte
steering and heat shield ⇒ Rep. gr. 40 ; Removing
ut
ho and installing eo
ra
subframe with steering rack . ss a c ce
le
– Now remove all upper connecting bolts from engine and gear‐
un
pt
an
d
y li
erm
pose.
ab
ility
ot p
h re
ole,
t to the co
f in
n
c
n thi
e
neath« the car. This will avoid having the weight of the engine
t
sd
va
o
pr
cum
r
long time«.
fo
en
ng
t.
yi Co
– Remove noise insulation and lower part of front left wheel Cop py
housing liner ⇒ General body repairs, exterior; Rep. gr. 66 ;
t. rig
gh ht
yri by
Removing and installing wheel housing liners; Front wheel op Vo
by c lksw
housing liners . cted agen
Prote AG.
– If fitted, remove the heat shield over the right-hand drive shaft.
Tightening torque ⇒ Rep. gr. 40 ; Repairing drive shafts
satelettronica
very good for this.
olkswagen AG
en AG. V
Secure both drive shafts to suspension struts using tensioningolks
wag does
not
straps - T10038- . ed
byV gu
ara
ris nte
– Unbolt ⇒ pendulum support from gearbox. utho eo
ra
a c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Next remove -subframe- together with -pendulum support- and
rrectness of i
-both suspension links- and -steering-.
For information on how to remove the -subframe-, refer to ⇒ Rep.
l purpos
a
com
removed.
r
te o
thi
s
iva
If the position of the subframe was not fixed, the wheels must now
do
r
rp
be aligned.
cum
fo
en
ng
t.
⇒ Running gear, axles, steering; Rep. gr. 40 ; Locating subframe
yi Co
op
and brackets .
C py
t. rig
gh ht
yri by
When removing subframe, please remember: cop Vo
by lksw
cted agen
Prote AG.
satelettronica
n AG. Volkswagen AG do
(At rearmost of the 3 support points of the battery tray)olkswage es n
ot g
V
by ua
– Remove filler pieces from upper edges of both
ris wings
ed ran
tee
tho or
s au ac
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
2 l - 103 kW engine
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
satelettronica
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted
– Support engine and gearbox. Do not raise.
agen
Prote AG.
Caution
satelettronica
– Remove remaining engine/gearbox connecting bolts.
– Press gearbox off engine while »observing selector lever ca‐
ble«, and lower gearbox.
Transporting gearbox and securing to assembly stand
⇒ page 283 .
Install gearbox ⇒ page 273 .
AG. Volkswagen AG d
agen
10.23 Removing gearbox, Scirocco 2009 ► Volksw
oes
not
gu
by
with 2.0 l petrol engine d ara
ise nte
or eo
h
ut ra
Brief description ss a c
ce
le
un
pt
an
d
y li
erm
ab
The battery, air filter and starter are removed. The coolant hoses
ility
ot p
wit
is n
h re
ole,
spec
»From below«
urposes, in part or in wh
t to the co
Remove -subframe- together with -pendulum support-,
-steering rack- and -both suspension links-.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
If the position of the -subframe- is not fixed with the pins, the
wheels must later be aligned.
In this case, wheel alignment would be unnecessary and costly
additional work! Save yourself this work and your customer the
expense!
It requires only a small effort to install the locating pins - T10096- .
Their benefit is enormous.
satelettronica
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
s c
satelettronica
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
♦ Support - 10-222A-
c
i
or
n thi
te
♦ Adapter - 10-222A/3-
sd
iva
o
pr
cum
r
en
ng
t.
yi Co
♦ Gearbox support - 3282- . Cop py
rig
ht ht
rig
♦ Adjustment plate - 3282/42 A- py by
co Vo
by lksw
cted agen
♦ Insert tool, 18 mm - T10179- Prote AG.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness
Special tools and workshop equipment required
o
cial p
f inform
♦ Tools without illustration:
mer
atio
♦ 2 x hose clamps, up to 40 mm - 3093-
om
n
c
i
or
n
♦ Or 2 hose clamps to 25 mm - 3094-
thi
te
sd
va
o
pr
cum
r
fo
satelettronica
en
Removing:
ng
t.
yi Co
op py
– Raise vehicle. All 4 supports of lifting platform must be at same t. C rig
gh ht
yri
height. p by
co Vo
by lksw
cted agen
– Move selector lever to position »P«. Prote AG.
satelettronica
Both securing clips must be later renewed when cable is adjusted.
Remove cable with great care from cable support bracket on
gearbox. Do not bend it. wage
n AG. Volkswagen AG do
e ks s no
Vol t
Cable may also be pushed ed slightly backwards out of cable support
by gu
ara
bracket and removedtholater
ris when gearbox is lowered. But then ntee
or
observe cable whens a lowering gearbox.
u ac
s
ce
e
pt
du
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
M6 nuts).
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
satelettronica
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Disconnect earth cable -2-.
es, in part or in w
t to the co
– Disconnect electrical connector -3-.
This wiring harness will later be removed together with the sub‐
frame. This way, you can avoid time-consuming work on the
rrectness of i
– Now remove all upper connecting bolts from engine and gear‐
nform
pose.
m
a
com
tio
thi
do
cum
fo
en
ng
t.
– Now separate steering from steering column.
yi Co
Cop py
t. rig
Refer to ⇒ Running gear, axles, steering; Rep. gr. 48 ; Removing
gh ht
pyri by
and installing steering rack to see what must be done.
co Vo
by lksw
cted agen
Prote AG.
In any case, first return the steering wheel to the straight-ahead
position. Engage steering wheel lock. Notes on tightening the bolt
can also be found in these instructions.
– Separate steering box from steering column.
It is advisable to now do all the work which must be done »be‐
neath« the car. This will avoid having the weight of the engine
carried by the support bar and, consequently, by the body, for »a
long time«.
– Remove noise insulation and lower part of front left wheel
housing liner ⇒ General body repairs, exterior; Rep. gr. 66 ;
Removing and installing wheel housing liners; Front wheel
housing liners .
– Remove left wheel housing liner.
– If fitted, remove the heat shield over the right-hand drive shaft.
Tightening torque ⇒ Rep. gr. 40 ; Repairing drive shafts
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
– Unbolt both transverse links from suspension struts.
ce
le
un
pt
an
d
y li
erm
ab
– Unbolt both drive shafts from gearbox and carefully lay to side.
ility
ot p
wit
is n
h re
ole,
spec
The surface protection of the shafts must not be damaged. Plastic
urposes, in part or in wh
t to the co
satelettronica
very good for this.
rrectness o
Secure both drive shafts to suspension struts using tensioning
cial p
f in
straps - T10038- .
form
mer
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
– Fit retainer - T10346- on longitudinal member.
ss
satelettronica
o
cial p
f
(At rearmost of the 3 support points of the battery tray)
inform
mer
atio
om
2 l - 147 kW engine
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
satelettronica
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
2.0 l diesel engine
hole
spec
es, in part or in w
Brief description
t to the co
satelettronica
The gearbox is removed downwards separately. »From above«
rrectness of i
The battery with battery tray, air filter and starter are removed.
The coolant hoses must be clamped off. Support engine and
l purpos
hicle.
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
♦ Support - 10-222A-
hole
spec
es, in part or in w
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
satelettronica
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing:
– Raise vehicle. All 4 supports of lifting platform must be at same
height.
– Move selector lever to position »P«.
Note agen
AG. Volkswagen AG d
satelettronica
oes
olksw not
V gu
by ara
After loosening centre bolt, do not lower risevehicle
d
to ground again. nte
ho eo
aut ra
s c
– Depress brake pedal to remove bolt for left drive shaft s
ce
le
pt
an
d
itte
y li
– Remove cover from engine.
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
a
com
en
ng
t.
– Remove complete air filter housing ⇒ Rep. gr. 24 ; Removing
yi Co
op py
and installing air filter . t. C rig
gh ht
pyri by
– Remove battery and battery tray ⇒ Rep. gr. 27 ; Battery; Re‐
o Vo
by c lksw
cted
moving and installing battery .
agen
Prote AG.
satelettronica
Both securing clips must be later renewed when cable is adjusted.
– Remove cable with great care from cable support bracket on
gearbox. Do not bend cable.
Cable can also be removed later on when gearbox is being low‐
ered. Then observe cable whilst lowering gearbox.
During later installation, do not clip »small« securing clips on until
cable has been checked and adjusted ⇒ page 70 .
AG. Volkswagen
agen AG do
ksw es n
y Vol ot g
ua
b
ed ran
oris tee
th or
au ac
ss
ce
le
un
pt
ab
pe
ility
wit
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
253
Prote AG.
10. Removing and installing gearbox
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
6-speed dual clutch gearbox 02E - Edition 01.2018
satelettronica
– Remove left drive shaft ⇒ Rep. gr. 40 . AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
– If present, remove heat shield above right drive shaft. Tight‐
ce
le
un
pt
ening torque ⇒ Rep. gr. 40 ; Repairing drive shafts
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
– Unbolt wiring retainer from front of »black« gearbox cover
s
-arrows- (2 nuts M6).
s o
cial p
f i
– Support engine and gearbox.
nform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
r
satelettronica
p
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
• Before putting on support bracket - 10-222 A- , note assembly
of following special tools:
• Adapters - 10-222 A /8- must be mounted as shown.
• Supports -A- must face outwards.
• -Arrow- = vehicle driving direction.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Set up support bracket - 10-222 A- behind bonnet support: hole
spec
es, in part or in w
t to the co
left side.
– Then fit support bracket - 10-222A- behind bonnet support.
rrectness of i
Position the right adapter - 10-222A/8- next to the bolts as well
-arrow-.
l purpos
satelettronica
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Attach bars - 2024 A / 1- in engine support eyes.
• 2 holes -arrows- each point towards front end.
– Connect lugs - 2024 A / 1- to spindle - 10 - 222 A /12- using
shackle - 10 - 222 A /10- .
(⇒ previous illustration)
– Set up adapter - T40093/3- with adapter - T40093/3-5 - (notch
-A-) on sheet metal fold of bumper carrier.
– Push one spindle onto square tube - T40091/1- .
– Assemble square tube - T40091/1- with adapter - T40093/3-
and support bracket - 10-222A- .
– Then attach spindle in front engine support eye.
– Take up weight of engine/gearbox assembly on spindle .
Note
Before removing flange shaft, check oil seal for leaks. If oil seal
is leaking, it must be renewed before flange shaft is installed.
satelettronica
– Close opening in drive shaft using a suitable plug.
– When flange shaft is reinstalled, compression spring prevents
bolt engaging in thread. If necessary press flange shaft against
gearbox with a lever and screw in bolt.
Specified torque: 30 Nm
– Set up gearbox support - 3282- with adjustment plate
agen -
AG. Volkswagen AG d
oes
3282/42 A- . olksw not
yV gu b ara
ed
– Move engine and gearbox jack - V.A.Gtho1383
ris A- under gearbox nte
e or
and support gearbox. Do not raise.s au ac
s
ce
le
pt
an
d
itte
ab
pe
ility
– Press gearbox off engine while »observing selector lever ca‐
ot
wit
ble«, and lower gearbox.
, is n
h re
hole
⇒ page 283 .
es, in part or in w
t to the co
Brief description
nform
ercia
a
com
tio
Remove battery with battery tray, air filter, starter and radiator
n in
r
thi
do
r
rp
cum
»From below«
fo
en
ng
t.
yi Co
⇒ Pendulum support and both flange shafts removed from gear‐ Cop py
box. The subframe remains in the vehicle.
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
satelettronica
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ Support - 10-222A-
♦ Adjustment plate - 3282/42 A-
♦ Adapter - 10 - 222 A /8-
♦ Socket insert - T10035-
♦ Gearbox support - 3282-
♦ Insert tool, 18 mm - T10179-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
satelettronica
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
en
g
t.
yi Co
op py
♦ Adapter - T40093/3- of supplementary engine support bracket
t. C rig
gh ht
yri
set - T40093- p by
o Vo
by c lksw
cted agen
♦ Hose clamps up to 40 mm - 3093- if available, or hose clamps
Prote AG.
up to 25 mm - 3094-
♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Adapter - T40093/3-5 - of supplementary engine support
bracket set - T40093-
♦ Socket insert - T10107 A-
Removing:
– Raise vehicle. All 4 supports of lifting platform must be at same
height.
– Move selector lever to position »P«.
Note
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
Use pliers to remove the securing clip on the cable support brack‐
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
at
ion
in t
or
his
te
do
riv
cum
for
en
g
t.
yi Co
op
cable has been checked and adjusted ⇒ page 70 . C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove upper engine/gearbox connecting bolts.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
satelettronica
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
– Unscrew right
s autransverse
t
link from suspension strut -arrows- ra
c
⇒ Rep. gr. s40 .
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
le
by bolts -2- and -3- ⇒ Rep. gr. 40 .
un
pt
an
d
itte
y li
erm
ab
Note
ility
ot p
wit
is n
h re
Before removing flange shaft, check oil seal for leaks. If oil seal
ole,
spec
is leaking, it must be renewed before flange shaft is installed.
urposes, in part or in wh
t to the co
rrectnes
– Remove »left« and »right« flange shafts from gearbox using
s o
cial p
f
insert -T10107 A- .
inform
mer
atio
installed using socket V.A.G 1669 .
om
n
c
i
or
n
– To remove or install flange shaft, screw 2 bolts into flange and
thi
te
sd
iva
o
pr
cum
r
satelettronica
en
ng
t.
yi Co
– Close opening in drive shaft using a suitable plug. . Cop py
rig
ht ht
rig
– When flange shaft is reinstalled, compression spring prevents py by
co Vo
bolt engaging in thread. If necessary press flange shaft against
by lksw
cted agen
Prote
gearbox with a lever and screw in bolt.
AG.
Specified torque: 30 Nm
ce
le
un
pt
– Push rotary joint - T40091/3- and adapter - 10 - 222 A /3- onto
an
d
itte
y li
square tube of support bracket - 10 - 222 A- .
erm
ab
ility
ot p
– Fit adapter - 10-222 A /8- as shown and bolt to support bracket
wit
- 10-222 A- . is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
op
• -Arrow- = vehicle driving direction.
py
satelettronica
t. C rig
gh ht
yri by
• Set up support bracket - 10-222 A- behind bonnet support. cop Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
satelettronica
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
spindle of support bracket - 10 - 222 A- .
ate
do
priv
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
satelettronica
Brief description
The gearbox is removed downwards
wage
n AG. Vseparately.
olkswagen AG»From above«
doe
ks s no
Vol t
The battery, air filtereand
d b starter are removed. The coolant
y gu
ahoses
ran
must be clampedhooff.ris Left subframe mounting is removed and tee
engine and gearbox
s aut
supported. or
ac
s
»From below«
ce
le
un
pt
an
d
itte
ab
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
satelettronica
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
♦ Support - 10 - 222 A-
by lksw
cted agen
Prote AG.
♦ Adjustment plate - 3282/42 A-
♦ Adapter - 10 - 222 A /8-
♦ Hose clamps to 25 mm - 3094-
♦ Gearbox support - 3282-
♦ Insert tool, 18 mm - T10179-
Special tools and workshop equipment required
♦ Tools without illustration:
♦ Tensioning strap - T10038-
♦ Engine and gearbox jack - V.A.G 1383 A-
Removing:
– Raise vehicle. All 4 supports of lifting platform must be at same
height.
– Move selector lever to position »P«.
– Remove cover from engine.
– Remove complete air filter housing ⇒ Rep. gr. 24 ; Removing
and installing air filter .
satelettronica
connector.
– Remove starter -A- ⇒ Electrical system; Rep. gr. 27 ; Re‐
moving and installing starter .
It is advisable to remove the »lower« bolt first.
– Unbolt earth strap from bracket.
AG. Volkswagen AG d
agen oes
– Remove selector lever cable from gearbox -arrows-. Volksw not
gu
by ara
ed
Use pliers to remove the securing clip on the cablehosupport
ris brack‐ nte
eo
et. Do not use a sharp-edged lever, as the rubber autgrommet on the ra
c
cable could be damaged. ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
atio
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
satelettronica
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
satelettronica
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
A bolt is located in the starter motor hole -arrow-. by c lksw
cted agen
Prote AG.
– Remove noise insulation and front left wheel housing liner ⇒
General body repairs, exterior; Rep. gr. 66 ; Removing and
installing wheel housing liner; Front wheel housing liner .
satelettronica
– Unbolt wiring retainer from front of »black« gearbox cover (2
nuts M6). swa
gen AG
. Volkswagen AG
does
k not
Vol gu
Specified torque: 10 Nm ed by ara
nte
ris
utho eo
ra
a c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
Remove following components before fitting support bracket:
an
d
itte
y li
rm
ab
♦ Windscreen wiper arms ⇒ Electrical system; Rep. gr. 92 ;
satelettronica
pe
ility
Windscreen wash/wipe system
ot
wit
, is n
h re
♦ Plenum chamber cover ⇒ Rep. gr. 50 ; Plenum chamber
hole
spec
cover
es, in part or in w
t to the co
Adapters - 10-222 A /8- for support bracket - 10-222 A- are placed
in area of plenum chamber cover.
rrectness of i
– Fit adapter - 10-222 A /8- as shown and bolt to support bracket
l purpos
- 10-222 A- .
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
satelettronica
– Remove remaining engine/gearbox connecting bolts.
AG. Volkswagen AG d
– Press gearbox off engine while »observing selector lever ca‐lkswagen oes
not
ble«, and lower gearbox. db
yV
o gu
ara
e nte
ris
Transporting gearbox and securing to assembly stand tho eo
⇒ page 283 . s au ra
c
s
ce
le
pt
an
d
itte
y li
erm
ab
10.27 Install gearbox
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
Crankshaft; Renewing needle bearing in crankshaft .
– Lightly grease journal and splines on gearbox using high-tem‐
rrectne
perature grease - G052133A2- .
– Check for proper seating of both dowel sleeves between en‐
ss
gine and gearbox.
o
cial p
f in
– Check for proper seating of intermediate plate.
form
mer
atio
It must be possible to guide the engine and gear box together by
om
i
or
n thi
e
sd
iva
o
pr
cum
en
ng
satelettronica
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
Consequently, further descriptions can also be found in ⇒ Run‐
un
pt
an
d
ning gear; Rep. gr. 40 .
itte
y li
erm
ab
The correct torque settings for the engine/gearbox combination
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
Petrol en‐ Eos Golf Golf Plus Scirocco Passat Touran Golf 2009 ► Sharan
gine 2006 ► 2004 ► 2009 ► 2006 ► 2003 ► 2011 ►
satelettronica
and Pas‐
rrectne
sat CC
2009 ►
s
1.4 l - 103 ⇒ ⇒ ⇒ ⇒
s o
cial p
f in
277 277
form
mer
1.4 l - ⇒ ⇒ ⇒
atio
m
n
c
i
or
n
277 277
thi
te
sd
a
1.4 l - ⇒
iv
o
pr
c
188 kW page 277
um
r
fo
en
ng
t.
2.0 l - ⇒ ⇒
yi Co
op
147 kW page page
C py
ht. rig
278 278
rig ht
py by
co Vo
by lksw
2.0 l - 147 ⇒ ⇒ ⇒ cted ⇒ ⇒ ⇒
agen
Prote AG.
- 155 kW page page page page page 276 page 276
276 276 276 276
2.0 l - ⇒
169 kW page
278
3.2 l - ⇒ ⇒ ⇒
184 kW page page page
280 281 281
3.6 and ⇒
3.6 l - V6 page
engine 282
Diesel en‐ Eos 2006 Scirocco Golf Golf Plus Passat Touran Golf Sharan
gine ► 2009 ► 2004 ► 2006 ► 2003 ► 2009 ► 2011 ►
and Pas‐
sat CC
2009 ►
1.9 l - ⇒ ⇒ ⇒
77 kW page 281 page 278 page 278
2.0 l - 81 ⇒ ⇒
kW and page 278 page 278
103 kW
Diesel en‐ Eos 2006 Scirocco Golf Golf Plus Passat Touran Golf Sharan
gine ► 2009 ► 2004 ► 2006 ► 2003 ► 2009 ► 2011 ►
and Pas‐
sat CC
2009 ►
2.0 l - ⇒
88 kW page 278
2.0 l - ⇒ ⇒ ⇒ ⇒
100 kW page 278 page 278 page 278 page 278
2.0 l - 103 - ⇒ ⇒ ⇒ ⇒ ⇒ ⇒
105 kW page 278 page 278 page 278 page 278 page 278 page 278
2.0 l - ⇒
120 kW page 278
2.0 l - 125 ⇒ ⇒ ⇒ ⇒ ⇒
kW page 278 page 278 page 278 page 278 page 278
satelettronica
for:
Scirocco 2009 ►, Golf 2009 ►, Golf Plus 2009 ►, Passat 2006 ►
and Passat CC 2009 ► Eos 2006 ► with 2.0 l - 147- 155 kW
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
M12 - 80 Nm
❑ If insert 18 mm -
T10179- is used: 65 Nm.
M10 - 40 Nm
- Arrows indicate dowel
sleeves.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
– Renew all bolts on left assembly mounting. s aut ra
c
s
– First screw in all bolts by hand.
ce
e
nl
pt
du
an
itte
ab
turn.
ility
ot p
h re
t to the co
atio
m
mountings
o
n in
or c
thi
e
for:
t
sd
iva
o
r
rp
cu
Golf 2004, Golf Plus 2005, Touran 2003 with 1.4 l - 103 and
o
m
f
en
ng
277
by lksw
cted agen
Prote 11. Torque settings »gearbox to engine«
AG.
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
6-speed dual clutch gearbox 02E - Edition 01.2018
M12 - 80 Nm
❑ If insert 18 mm -
T10179- is used: 65 Nm.
M10 - 40 Nm
- Arrows indicate dowel
sleeves.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
satelettronica
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
o Vo
– Renew all bolts on left assembly mounting. by c lksw
cted agen
Prote AG.
– First screw in all bolts by hand.
– First bolt bracket -A- to gearbox -1- with 40 Nm + 90° further
turn.
– The bracket can be levered into the correct position with a
screwdriver as bolts -2- are tightened. Torque settings of
-bolts 2-: 60 Nm + 90°.
Starter to gearbox ⇒ Rep. gr. 27 ; Removing and installing start‐
er .
Assembly mounting bolts must be renewed.
Subframe to body ⇒ Rep. gr. 40 ; Assembly overview - subframe,
anti-roll bar, suspension links .
♦ Golf with 1.9 l - 77 kW and 2.0 l - 100, 103 and 125 kW »diesel
engines«
♦ Golf Plus with 1.9 l - 77 kW and 2.0 l - 100, 103 and 125 kW
»diesel engines«
♦ Touran with 1.9 l - 77 kW and 2.0 l - 100, 103 and 125 kW
»diesel engines«
♦ Passat and Passat CC with 1.9 l - 77 kW and 2.0 l - 88, 100,
103 and 125 kW »diesel engines«
♦ Eos with 2.0 l - 147 kW »petrol engines«
♦ Eos with 2.0 l - 103 kW »diesel engines«
♦ Scirocco »diesel engine«: 2.0 l - 103 kW
♦ Sharan with 2.0 l - 100, 103 and 125 kW »diesel engines«
M12 - 80 Nm
❑ If insert 18 mm -
T10179- is used: 65 Nm.
M10 - 40 Nm
satelettronica
- Arrows indicate dowel
sleeves.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
a
com
tio
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
279
by c lksw
cted
11. Torque settings »gearbox to engine«
agen
Prote AG.
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
6-speed dual clutch gearbox 02E - Edition 01.2018
ce
e
nl
pt
du
an
mountings
itte
y li
erm
ab
ility
for:
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
M12 - 80 Nm
satelettronica
❑ If insert 18 mm -
T10179- is used: 65 Nm.
rrectness of i
M10 - 40 Nm
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
– First bolt bracket -A- to gearbox -1- with 40 Nm + 90° further nl
pt
du
an
turn.
itte
y li
erm
ab
– The bracket can be levered into the correct position with a
ility
ot p
wit
, is n
h re
hole
spec
Starter to gearbox ⇒ Rep. gr. 27 ; Removing and installing start‐
es, in part or in w
er .
t to the co
Assembly mounting bolts must be renewed.
Subframe to body ⇒ Rep. gr. 40 ; Assembly overview - subframe,
rrectness of i
anti-roll bar, suspension links .
l purpos
nform
ercia
mountings
m
at
om
ion
for:
c
in t
or
his
te
Golf 2004 and Passat 2006 with 3.2 l - V6 engine (all-wheel drive)
a
do
priv
cum
satelettronica
for
en
ng
t.
M12 - 80 Nm
yi Co
Cop py
❑ If insert 18 mm -
t. rig
gh ht
yri by
T10179- is used: 65 Nm. cop Vo
by lksw
cted agen
Prote
M10 - 40 Nm
AG.
Propshaft
♦ Drive shaft heat shield to bevel box: 25 Nm
♦ Propshaft to bevel box ⇒ Final drive 02D, 0AV (01Z); Rep. gr.
39 ; Removing and installing propshaft
– Renew all bolts on left assembly mounting.
– First screw in all bolts by hand.
– First bolt bracket -A- to gearbox -1- with 40 Nm + 90° further
turn.
– The bracket can be levered into the correct position with a
screwdriver as bolts -2- are tightened. Torque setting of
-bolts 2-: 60 Nm + 90°. AG. Volkswagen AG d
agen oes
ksw
Starter to gearbox ⇒ Rep. gr. 27 ; Removing and installing start‐
byV
ol not
gu
ara
er . rised
nte
ho eo
ut
Assembly mounting bolts must be renewed. ss a ra
c
ce
le
pt
an
anti-roll bar, suspension links .
d
itte
y li
erm
ab
ility
satelettronica
ot p
wit
is n
h re
ole,
mountings
spec
urposes, in part or in wh
for:
t to the co
3.2 and 3.6 l - V6 engine
rrectne
Gearbox to engine
Bolts M12 “80 Nm”
ss o
• If insert 18 mm - T10179- is used: 65 Nm.
cial p
f inform
Bolts M10 “40 Nm”
mer
atio
m
Propshaft
o
n
c
i
or
n thi
♦ Drive shaft heat shield to bevel box: 25 Nm
te
sd
iva
o
r
♦ Propshaft to bevel box ⇒ Final drive 02D, 0AV (01Z); Rep. gr.
p
cum
r
fo
t.
yi Co
op
Assembly mountings
C py
ht. rig
rig ht
py by
– Renew all bolts on left assembly mounting. co Vo
by lksw
cted agen
Prote AG.
– First screw in all bolts by hand.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
satelettronica
hole
spec
Gearbox may also be lifted with gearbox lifting tackle - 3336- .
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Removing
wit
, is n
h re
spec
t to the co
height.
– Remove front right wheel.
rrectness of i
-arrows-.
m
at
om
in t
or
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove retainer -2- for electrical cable to oil level and oil tem‐
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
satelettronica
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
– Remove bolts -1- and -2- from bevel box bracket.
Prote AG.
13. Removing and installing bevel box, Golf 2004 ► and Passat 2006 ► 285
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
6-speed dual clutch gearbox 02E - Edition 01.2018
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
– Push propshaft horizontally as far back as possible.ut
ho eo
ra
s a c
s
ce
le
Caution
un
pt
an
d
itte
y li
erm
ab
♦ Seal -arrow- in flange of propshaft must not be damaged
ility
ot p
wit
must be renewed.
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
– Unscrew bolts -2- and -3-.
ss
– Push engine and gearbox forwards slightly and then pull prop‐
o
cial p
falling down.
o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Remove subframe.
For information on how to remove the -subframe-, refer to ⇒ Rep.
gr. 40 . If the job is done correctly, the subframe can be removed
and reinstalled without subsequently causing increased tyre
wear, which may lead to customer complaints. It is recommended
to read this information »before« removing gearbox. Then the
position of the -subframe- can be properly fixed and the subframe
removed.
– Place used oil collection and extraction unit - V.A.G 1782- be‐
low gearbox.
ce
le
un
pt
Installing
an
d
itte
y li
rm
ab
satelettronica
pe
ility
the following:
ot
wit
, is n
– Push bevel box together with flange shaft onto gearbox while
h re
hole
spec
es, in part or in w
t to the co
Specified torque
rrectness of i
40 Nm
l purpos
a
com
tion in
thi
s
do
r
rp
cum
en
ng
t.
yi Co
– Press engine/gearbox towards bulkhead panel, carefully guid‐ Cop py
t. rig
ing bevel box pin into propshaft flange. opyri
gh by
Vo
ht
c by lksw
cted agen
Prote AG.
13. Removing and installing bevel box, Golf 2004 ► and Passat 2006 ► 287
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
6-speed dual clutch gearbox 02E - Edition 01.2018
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
satelettronica
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
♦ or Socket - T10107 A-
com
tion in
r
♦ Puller - T10037-
te o
thi
s
iva
do
cum
fo
en
g
♦ Cap - T10460-
n
t.
yi Co
op py
♦ Torque wrench - V.A.G 1331-
. C rig
ht ht
rig by
opy Vo
Special tools and workshop equipment required by c lksw
cted agen
Prote AG.
14. Removing and installing bevel box, Passat CC 2009 ►, CC 2010 ► with diesel engine 289
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
6-speed dual clutch gearbox 02E - Edition 01.2018
Removing
– Raise vehicle. All 4 supports of lifting platform must be at same
height.
– Move selector lever to position »P«.
Note
satelettronica
After loosening centre bolt, do not lower vehicle to ground again.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
ab
pe
ility
ot
particulate filter .
es, in part or in w
t to the co
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
In vehicles with auxiliary heater, a bracket for coolant hoses is
itte
y li
erm
also removed with heat shield. When installing, first place bracket
ab
ility
onto threaded pins and only then install heat shield.
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Only vehicles with auxiliary heater:
l purpos
nf
ercia
o
gearbox carrier can be unscrewed ⇒ Auxiliary heater; Rep.
rm
m
atio
gr. 82 ; Removing and installing Thermo Top V auxiliary heat‐
om
er .
n in
or c
thi
e
sd
iva
satelettronica
r
rp
cu
Continued for all vehicles:
o
m
f
en
ng
t.
yi
– Remove right drive shaft ⇒ Running gear, axles, steering;
Co
op py
Rep. gr. 40 ; Removing and installing drive shafts .
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove lower bracket for diesel particulate filter ⇒ Rep. gr.
26 ; Removing and installing particulate filter .
14. Removing and installing bevel box, Passat CC 2009 ►, CC 2010 ► with diesel engine 291
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
6-speed dual clutch gearbox 02E - Edition 01.2018
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
– Push engine/gearboxdto by front end and support using pendulum
V gu
ara
support as shown.oris e nte
eo
h
ut ra
-A- = Collar bolt M10
ss a
x 35 c
ce
le
un
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Unscrew and remove oil drain plug -A- from bevel box and
rrectness of i
allow oil to drain out. Then screw in new bolt and tighten to 15
l purpos
Nm.
Some vehicles have an intermediate flange on flange shaft/bevel
nform
ercia
box.
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove countersunk bolt for right flange shaft with socket -
l purpos
nform
ercia
at
om
ion
c
in t
or
his
ate
do
riv
satelettronica
p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Now bolt puller - T10037- to right flange shaft.
Note
14. Removing and installing bevel box, Passat CC 2009 ►, CC 2010 ► with diesel engine 293
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
6-speed dual clutch gearbox 02E - Edition 01.2018
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
u ra
satelettronica
s a c
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
gearbox. spec
es, in part or in w
Installing
rrectness of i
tio
thi
s
iva
do
cum
en
ng
t.
yi Co
Cop py
t. rig
gh
Note
ht
pyri by
Vo
co lksw
by
cted agen
Prote
Do not use securing bolts to pull bevel box onto gearbox, or bevel
AG.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
– Bolt bevel box carrier to engine and bevel box, observing tight‐
ce
e
nl
pt
du
an
itte
y li
– Install support for turbocharger -arrow- ⇒ Rep. gr. 21 ; As‐
erm
ab
sembly overview - turbocharger .
ility
ot p
wit
, is n
h re
do so, in order to avoid damaging bearings.
hole
spec
es, in part or in w
t to the co
que ⇒ Item 13 (page 324)
Continue installation in reverse order of removal.
rrectness of i
– Fill bevel box with axle oil ⇒ page 334 .
l purpos
orm
atio
om
n in
or c
sd
a
♦ Renew bolts
iv
o
r
rp
cu
o
m
f
Intermediate flange on 70 Nm
en
ng
t.
yi
right flange shaft
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
14. Removing and installing bevel box, Passat CC 2009 ►, CC 2010 ► with diesel engine 295
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
6-speed dual clutch gearbox 02E - Edition 01.2018
Allocation of bolts for bevel box carrier to engine and bevel box
Item Bolt Quantity
A M10 x 21 2
B M10 x 45 2
– Screw in all bolts hand-tight.
– Tighten bolts -B- to 40 Nm.
– Tighten bolts -A- to 40 Nm.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
satelettronica
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
satelettronica
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Removing:
nform
ercia
at
om
i
height.
on
c
in t
or
do
riv
cum
for
t.
yi
Front wheel housing liner .
Co
Cop py
t. rig
gh
– Unbolt right drive shaft from gearbox⇒ Rep. gr. 40 ; Removing
ht
pyri by
Vo
o
and installing drive shafts . by c lksw
cted agen
Prote AG.
– Use tensioning strap - T10038- to secure drive shafts on sus‐
pension strut.
– Remove pendulum support ⇒ Rep. gr. 40 ; Assembly over‐
view - subframe, anti-roll bar, suspension links .
15. Removing and installing bevel box, Passat CC 2009 ►, CC 2010 ► with 3.6 l V6 engine 297
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
6-speed dual clutch gearbox 02E - Edition 01.2018
satelettronica
The -seal- in the propshaft must not be damaged.
. Volkswag AG en AG
agen does
olksw not
yV gu
db ara
rise nte
tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
– Remove heat shield above right drive shaft -1- ⇒ Rep. gr. 40 ;
Heat shields for drive shafts .
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
satelettronica
– Unbolt bevel box from gearbox -arrows- and remove it.
To remove bevel box, push engine forwards slightly (second me‐
chanic).
Installing
Install in reverse order of removal. During this procedure, observe
the following:
. Volkswagen AG
gen AG does
– Push bevel box together with flange shaft onto gearbox while
Vol
ksw
a
not
turning flange shaft. ed by gu
ara
ris nte
ho eo
– Bolt bevel box onto gearbox using 4 new bolts. aut ra
ss c
Specified torque ce
e
nl
pt
du
an
40 Nm
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
299
AG.
15. Removing and installing bevel box, Passat CC 2009 ►, CC 2010 ► with 3.6 l V6 engine
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
6-speed dual clutch gearbox 02E - Edition 01.2018
– Install heat shield above right drive shaft -1- ⇒ Rep. gr. 40 ;
Heat shields for drive shafts .
– Bolt right drive shaft to gearbox⇒ Rep. gr. 40 ; Removing and
installing drive shafts .
– Install pendulum support ⇒ Rep. gr. 40 ; Assembly overview
- subframe, anti-roll bar, suspension links .
– Bolt propshaft to bevel box -arrows- ⇒ Rep. gr. 39 ; Removing
satelettronica
and installing propshaft .
– Bolt exhaust system bracket to subframe -arrows- ⇒ Rep. gr.
26 ; Exhaust system .
Continue installation in reverse order of. removal.
gen AG
Volkswagen AG
d wa oes
olks not
byV gu
ara
ed nte
ris
tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
le
pt
an
d
itte
y li
rm
ab
pe
ility
Note
ot
wit
, is n
h re
The dimension -a- is measured from the shaft (green area in the
hole
spec
magnifying glass) of the adapter for oil filling - VAS 6262 A- .
es, in part or in w
t to the co
satelettronica
rrectness of i
– Mark dimension -a- on the breather pipe and shorten pipe with
pipe cutter - VAS 6056/2- .
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
16.1 Oil filter: renewing
by lksw
cted agen
Prote AG.
Note
Removing
– Move selector lever to position »P«.
– Removing air filter ⇒ Rep. gr. 24 ; Removing and installing
air filter .
– Remove battery with battery tray ⇒ Rep. gr. 27 ; Battery;
Removing and installing battery .
Note
satelettronica
– Screw in filter housing and tighten to 30 Nm.
Continue installation in reverse order of removal.
– Check oil level and top up ⇒ page 302 .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
16.2 Checking oil level and topping up au ra
ss c
ce
e
nl
pt
If DSG oil must be added, use only oil listed in ⇒ Electronic parts
du
an
itte
catalogue “ETKA” .
y li
erm
ab
ility
Special tools and workshop equipment required
ot p
wit
, is n
5051B-
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
satelettronica
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
Conditions ss
ce
e
nl
pt
du
height
y li
erm
ab
♦ Noise insulation removed ility
ot p
wit
, is n
5051B- is connected.
spec
es, in part or in w
Check
l purpos
atio
n in
or c
thi
te
sd
iva
Note
o
r
rp
cu
o
m
f
en
ng
ce
e
nl
pt
du
satelettronica
an
– Let surplus oil flow out.
itte
y li
erm
ab
– When excess oil has run out (when it begins only to drip), in‐
ility
ot p
spec
es, in part or in w
Topping up t to the co
– Before screwing adapter for oil filling - VAS 6262 A- onto oil
bottle, measure length of breather pipe, dimension -a- and
rrectness of i
or
Note
m
m
atio
om
n in
c
The dimension -a- is measured from the shaft (green area in the
or
thi
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
satelettronica
t or
au ac
An oil level which is too low sor
s too high will impair the function
of the gearbox.
ce
e
nl
pt
du
an
itte
y li
erm
ab
Torque setting for drain plug: 45 Nm
ility
ot p
wit
, is n
h re
16.3 Draining and filling oil
hole
spec
es, in part or in w
If DSG oil must be added, use only oil listed in ⇒ Electronic parts
t to the co
catalogue “ETKA” .
Brief description
rrectness of i
First read the oil temperature. If it is above 50°C, allow the gear‐
l purpos
the oil drain out. Then reinstall overflow pipe and »overfill« gear‐
orm
atio
om
n in
Then start engine and drain excess oil until oil level attains level
or c
of overflow pipe.
thi
te
sd
iva
o
r
cu
o
m
f
en
ng
satelettronica
Conditions
♦ Engine switched off
♦ Vehicle level, all mountings AG. Volkswagen AG devenly at same
agenof lifting platform oes
ksw
height by
Vol not
gu
d ara
se nte
♦ Noise insulation
tho
ri removed if previously fitted e or
au ac
♦ Selector slever
s
at “P”
ce
e
nl
pt
du
5051B- is connected.
y li
erm
ab
ility
wit
, is n
Procedure
h re
hole
spec
t to the co
WARNING
nf
orm
m
atio
om
n in
c
thi
sd
iva
o
r
rp
cu
m
f
en
ng
t.
yi
– Select Check oil level .
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
le
un
pt
If the oil temperature is higher than 45°C, allow gearbox to cool
an
d
itte
y li
down.
rm
ab
pe
ility
ot
wit
, is n
h re
WARNING
hole
spec
es, in part or in w
t to the co
– Engine switched off - do not start engine!
rrectness of i
– Remove oil drain plug close to pendulum support -arrow-.
l purpos
nform
ercia
a
com
tion in
r
te o
thi
s
iva
satelettronica
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove oil level pipe -arrow- and allow oil to run out.
Approximately 5 litres of oil will run out.
– Screw oil level pipe back in to stop and tighten to 3 Nm.
– Before screwing adapter for oil filling - VAS 6262 A- onto oil
bottle, measure length of breather pipe, dimension -a- and
shorten ⇒ page 301 .
Dimension -a- = 210 mm
Note
The dimension -a- is measured from the shaft (green area in the
magnifying glass) of the adapter for oil filling - VAS 6262 A- .
satelettronica
a c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
– Tighten oil drain plug -A- only until finger tight.
hole
spec
– Start engine.
es, in part or in w
t to the co
– Depress brake pedal and select each selector lever position
for about 3 seconds, then move lever back to »P«
rrectness of i
– Do NOT switch off engine.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
35 – Gears, shafts
1 Currently, no repairs can be made to
gears and shafts
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
satelettronica
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
❑ All-wheel drive only
rm
ab
pe
ility
2 - Seal for propshaft
ot
wit
, is n
⇒ page 318
h re
hole
spec
es, in part or in w
⇒ page 55
t to the co
4 - »Left« seal ⇒ page 313
5 - Seal »right«
rrectness of i
❑ Front-wheel drive
l purpos
⇒ page 311
❑ All-wheel drive
satelettronica
nform
ercia
⇒ page 325
m
tio
⇒ page 331 n in
r
te o
thi
do
seal
r
rp
cum
fo
❑ All-wheel drive
en
ng
t.
yi
⇒ page 314
Co
Cop py
t.
❑ Front-wheel drive
rig
gh ht
yri by
⇒ page 311 op Vo
by c lksw
cted agen
Prote AG.
Never loosen both securing bolts in left and right flange shafts at
the same time. If the differential bevel gears turn, it is difficult to
reinstall the bolts.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
ho
♦ Torque wrench - V.A.G 1331-aut or
ac
ss
ce
e
nl
pt
du
satelettronica
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
at
om
ion
Removing
c
in t
or
his
te
do
priv
cum
or
en
g
t.
yi Co
op
sulation C py
t. rig
gh ht
yri by
– Remove right drive shaft ⇒ Running gear, axles, steering; cop Vo
by lksw
Rep. gr. 40 ; Repairing drive shafts; Removing and installing cted agen
Prote AG.
drive shafts .
Vehicles with intermediate shaft
– After removing right drive shaft -A-, unbolt intermediate shaft
-B- from mounting bracket -C- -arrows- and pull out stub shaft
of gearbox.
Continued for all vehicles
– Place drip tray under gearbox.
n AG. Volkswagen AG do
lkswage es n
o ot g
– Drive in new seal to stop, being careful not to cant d bseal.
yV ua
ran
ir se tee
o
– Insert stub shaft or flange shaft. auth or
ac
ss
– Screw in new countersunk bolt for securing stub shaft or flange
ce
e
nl
pt
shaft and tighten to 30 Nm.
du
an
itte
y li
Vehicles with intermediate shaft
erm
ab
ility
ot p
wit
, is n
satelettronica
h re
– Grease splines of stub shaft with grease for clutch plate
hole
spec
splines - G 000 100- .
es, in part or in w
t to the co
rrectness of i
– Guide intermediate shaft -B- through mounting bracket -C-
onto stub shaft of gearbox.
l purpos
nform
ercia
at
Continued for all vehicles
om
ion
c
in t
r
his
e
do
riv
shafts .
p
cum
for
en
g
t.
yi Co
op
44 ; Torque settings for mounting wheels . C py
t. rig
gh ht
yri
– Check oil level and top up ⇒ page 302 .
p by
co Vo
by lksw
cted agen
Prote
– Install noise insulation ⇒ General body repairs, exterior; Rep.
AG.
2 Renewing oil seal for left flange shaft - front and all-wheel drive
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
atio
n in
or c
sd
iva
Removing
o
r
rp
cu
o
m
f
en
• Gearbox is installed.
ng
t.
yi Co
op py
– Remove wheel. t. C rig
gh ht
pyri by
– Remove centre and left parts of noise insulation below engine
o Vo
by c lksw
cted agen
and gearbox, if fitted. Prote AG.
2. Renewing oil seal for left flange shaft - front and all-wheel drive 313
AG. Volkswagen AG d
agen oes
olksw not
yV gu
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf ed 2009 ➤ , Golf Plus 2005 ➤ ...
b ara
nte
ris
6-speed dual clutch gearbox 02E - Edition
ut
h 01.2018
o eo
ra
s a c
s
– Remove flange shaft securing bolts by screwing 2 bolts into
ce
e
nl
pt
du
flange and counterholding flange shaft with a lever.
an
itte
y li
erm
ab
– Pull out flange shaft with compression spring.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
Installing
om
n in
c
– Half-fill space between sealing lip and dust lip with sealing
or
thi
e
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi
satelettronica
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2.1 Renewing oil seal for right flange shaft - all-wheel drive
ce
e
nl
pt
du
equipment required
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi
satelettronica
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ Puller - T10037-
♦ Thrust piece - T10049-
♦ Torque wrench - V.A.G 1331-
♦ Torque wrench - V.A.G 1332-
♦ Hexagon key - V.A.G 1669- or socket and extended bit -
T10107-
Removing
• Gearbox is installed.
WARNING
2. Renewing oil seal for left flange shaft - front and all-wheel drive 315
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
6-speed dual clutch gearbox 02E - Edition 01.2018
satelettronica
– Attach drive shaft heat shield to bevel box.
– Check oil level in bevel box ⇒ page 333 .
– Install noise insulation, if part of original equipment.
Specified torques
Heat shield for drive shaft to bevel box 25 Nm
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
e
satelettronica
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
r
his
ate
do
riv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Renewing oil seal for left flange shaft - front and all-wheel drive 317
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
6-speed dual clutch gearbox 02E - Edition 01.2018
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
♦ Grip tool - V.A.G 1582/6A-
ole,
spec
urposes, in part or in wh
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3. Renewing oil seal for propshaft drive flange at bevel box 319
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se
CC 2010 th ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009e o➤ ,
o te
Golf Plus 2005 ➤ ...
u r
6-speed
ss
a
dual clutch gearbox 02E - Edition 01.2018 ac
ce
le
un
pt
♦ Puller hooks VW 771/37
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op py
satelettronica
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
The bevel box oil seal for the output flange can only be renewed
with the bevel box removed.
satelettronica
screwing in M10x30 bolts -arrows-.
– Unscrew hexagon nut for output flange.
A - 36 mm socket for 3/4" drive
– Swing bevel box so that output flange points upwards.
output flange is pulled off. Inner ring is then pulled off output flange
un
pt
an
d
⇒ page 321 .
itte
y li
erm
ab
ility
ot p
h re
ole,
spec
urposes, in part or in wh
– Pull inner tapered roller bearing race off output flange using
t to the co
Note
s
1582/6A- .
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
by
321
copy Vo
by lksw
cted 3. Renewing oil seal for propshaft drive flange at bevel box
agen
Prote AG.
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
6-speed dual clutch gearbox 02E - Edition 01.2018
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
• Old shim -2- for preloading bearing of shaft bevel gear -1- must
be installed.
– Lay tapered roller bearing inner race -3- in outer race in bevel
rrectness of i
box.
l purpos
– Lightly oil outer circumference of new seal -4- for output flange.
nform
ercia
satelettronica
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
satelettronica
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Renewing oil seal for propshaft drive flange at bevel box 323
AG. Volkswagen AG d
agen oes
olksw not
byV gu
a
CC 2010 ➤ , Eos 2006 ➤ , Golfris2004 ➤ , Golf 2009 ➤ , Golf Plus 2005ra➤
ed
nte...
o eo
6-speed dual clutch gearboxau02E
th - Edition 01.2018 ra
ss c
ce
e
nl
pt
du
4 Assembly overview - Flange shafts and seals on bevel box
an
itte
y li
erm
ab
ility
ot p
wit
1 - Hexagon nut
, is n
h re
❑ For output flange
hole
spec
❑ Always renew, ⇒ Elec‐
es, in part or in w
t to the co
tronic parts catalogue
❑ 480 Nm
rrectness of i
2 - Bevel box output flange
l purpos
nf
ercia
orm
m
4 - Seal
atio
om
n in
or c
thi
te
sd
a
o
r
rp
cu
page 318
o
m
f
en
ng
t.
5 - Seal
yi Co
satelettronica
Cop py
❑ ⇒ “4.5 Renewing seal on ht. rig
rig ht
bevel box between
py by
co Vo
by lksw
gearbox and bevel box”, Prote
cted AG.
agen
page 331
6 - Bevel box
❑ Removing and installing
⇒ page 284
7 - Oil drain plug
❑ For bevel box
❑ Bolt M6; 15 Nm
❑ Bolt M8; 60 Nm
8 - Seal
❑
9 - Filling and inspection plug
❑ For bevel box
❑ Always renew, ⇒ Electronic parts catalogue
❑ 15 Nm
10 - Bolt
❑ Attachment of bevel box to gearbox
❑ Qty. 4
❑ 30 Nm
11 - Breather pipe
12 - Breather cap
13 - Countersunk bolt
❑ Always renew
❑ 30 Nm
14 - Right flange shaft
❑ ⇒ “4.2 Removing and installing right flange shaft”, page 326
15 - Seal
❑ Always renew after removing right flange shaft
16 - Bearings
❑ Needle bearing (polygon bearing) is difficult to turn with flange shaft removed The fact it is difficult to
move does not mean that the bearing is defective. An acoustic test can only be performed with the
bearings installed.
❑ Inspect for signs of damage to bearings, such as cracking in outer race, and renew if necessary.
❑ ⇒ “4.4 Renewing needle bearing (polygon bearing) for right output shaft drive flange”, page 329
17 - Bearings
❑ Needle bearing (polygon bearing) is difficult to turn with flange shaft removed The fact it is difficult to
move does not mean that the bearing is defective. An acoustic test can only be performed with the
bearings installed.
❑ Inspect for signs of damage to bearings, such as cracking in outer race, and renew if necessary.
❑ ⇒ “4.4 Renewing needle bearing (polygon bearing) for right output shaft drive flange”, page 329
18 - Retaining ring
❑ Always renew after removing
satelettronica
Special tools and workshop equipment required
♦ Extractor hooks -T20143-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Procedure
– Remove bevel box ⇒ page 284 .
nform
ercia
Place used oil collection and extraction unit - V.A.G 1782- below
m
at
om
i
gearbox.
on
c
in t
or
his
ate
T20143/2- .
do
riv
satelettronica
p
cum
or
– Fill space between sealing lip and dust lip -arrow- with sealing
f
en
ng
t.
yi
grease - G 052 128 A1- .
Co
Cop py
t. rig
gh
– Lightly oil outer circumference of oil seal.
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
satelettronica
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
op
♦ Used oil collector and extractor - V.A.G 1782- C py
t. rig
gh ht
yri
♦ Puller - T10037-
p by
o Vo
by c lksw
cted agen
♦ Socket insert - T10107-
Prote AG.
Removing
– Remove right drive shaft ⇒ Running gear - front and four-
wheel drive; Rep. gr. 40 .
– Unbolt heat shield for right drive shaft from bevel box
-arrows-.
– Place used oil collection and extraction unit - V.A.G 1782- be‐
low gearbox.
– Remove countersunk bolt for right flange shaft with socket -
T10107- by screwing 2 bolts into flange and counterholding
flange shaft with a lever.
satelettronica
rise nte
ho eo
Renew flange shaft countersunk
t
s au bolt. ra
c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
– Remove seal -A- from groove -arrow- and renew.
ot p
wit
is n
spec
– Secure flange shaft with new countersunk bolt, torque speci‐
urposes, in part or in wh
Specified torques
s o
cial p
f in
Component Nm
form
mer
atio
n
c
i
or
n thi
e
sd
iva
o
pr
en
ng
t.
yi Co
Special tools and workshop equipment required Cop py
t. rig
gh ht
yri
♦ Thrust piece - T10049- p by
co Vo
by lksw
cted agen
Prote AG.
Procedure
The seal can be renewed with gearbox installed.
– Remove right flange shaft ⇒ page 326 .
– Lever out flange shaft oil seal with assembly lever.
– Drive in new oil seal toAGstop
. Volkusing
swagenthrust piece - T10049- .
agen AG do
ksw es n
y Vol ot g
ua
b
ed ran
oris tee
th or
au ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
– Fill space between sealing lip and dust lip -arrow- with sealing
grease - G 052 128 A1- .
satelettronica
rrectne
– Install right flange shaft ⇒ page 326 .
– Check oil level in bevel box and top up ⇒ page 333 .
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
4.4 Renewing needle bearing (polygon bearing) for right output shaft drive
Cop py
t. rig
gh
flange
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
♦ Thrust plates - VW 401-
s c
ce
le
un
pt
y li
erm
h re
ole,
Procedure
– Remove right flange shaft ⇒ page 326 .
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
330
Prote AG.
Rep. gr.39 - Final drive - differential
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
6-speed dual clutch gearbox 02E - Edition 01.2018
satelettronica
n AG. Volkswagen AG do
lks wage es n
– Turn shaft while pressing
byV
o it off -arrow-. This will prevent
ot g
ua dam‐
age to bearing o
ir srace
ed on shaft. ran
tee
th or
u
– Secure bearing
ss
a with a new retaining ring. ac
ce
le
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Procedure
– Remove bevel box ⇒ page 284 .
– Lever out seal on bevel box using puller hook - T20143/1- or
- T20143/2- .
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
– Fill space between sealing olip
ris and dust lip -arrow- with sealing
e nte
eo
grease - G 052 128 A1-a.uth
ra
ss c
– Lightly oil outer circumference of oil seal.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
satelettronica
♦ For some oil bottles adapter - VAS 6262/6- must be used as
well. agen
AG. Volkswagen AG d
o w es n
olks ot g
byV ua
ed ran
ris tee
tho or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
logue “ETKA” .
orm
m
Requirement
atio
om
n in
c
thi
te
sd
a
o
r
rp
cu
m
f
en
ng
t.
– Place drip tray for workshop hoist - VAS 6208- underneath.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
333
Prote AG.
5. Checking and topping up gear oil in bevel box
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ...
6-speed dual clutch gearbox 02E - Edition 01.2018
Note
satelettronica
• Vehicle is level.
– To top up oil, use filler device - VAS 6291- .
– Route hose of filler device - VAS 6291- behind right drive shaft
through right wheel housing to outside.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
Note
t to the co
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
satelettronica
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
– Engage elbow -B- in adapter -A-.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
i
or
n thi
e
sd
iva
lustration.
pr
cum
r
fo
en
ng
Note
♦ If bevel box has been properly filled, oil will have run out at
adapter -A-.
♦ Continue with filling procedure if no oil has run out yet.
satelettronica
– Turn off engine and unscrew plug from oil filler hole.
– Check oil level, if necessary top up gear oilagagain
en AG.to
Volower
lkswageedge
n AG d
oes
of filler hole. olksw not
y V g ua
b
ed ran
– Install new oil filler plug -arrow-
ho
risand tighten to 15 Nm. tee
t or
au ac
If oil should get on bevel box,ss carefully remove it.
ce
le
un
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.