Manual Transmision 0BH PDF

Service
Workshop Manual
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Service Department. Technical Information

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

No reproduction without prior agreement from publisher.
Copyright © 2017 Volkswagen AG, Wolfsburg D3E802C2DEC

Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 General safety provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 2
1.3 Notes on tow-starting/towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Safety precautions when using testers and measuring instruments during a road test . . . . 2
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Identification of gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 Allocation gearbox - engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.1 Overview of fitting locations - electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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30 - Clutch . . . . . . . . . .Vo.lk.sw. a.g . . . . . . . . . . . . d.oe.s.no.t g. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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1 Clutch . . .ri.se.d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ra.nt.e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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1.1 Assembly aut overview - dual clutch . . . . . . . . . . . . . . . . .o.r a. . . . . . . . . . . . . . . . . . . . . . . . . . 11
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1.2 Removing and installing clutch end cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.3 Removing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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

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34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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1 Mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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1.1 Removing and installing mechatronic unit for dual clutch gearbox J743 (gearbox installed)
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1.2 Removing and installing mechatronic unit for dual clutch gearbox J743 (gearbox removed)
........................................................................ 31
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1.3 Removing and installing gearbox input speed sender G182 and oil temperature sender in
multi-plate clutch G509 up to gearbox date 05/15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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2 Removing and installing gear oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

2.1 Renewing bleeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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3 Emergency release of selector lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

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4 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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4.1 Removing and installing handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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4.2 Moving push button in the handle to installation position . . . . . . . . . . . . . . . . . . . . . . . . . . 45

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5 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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5.1 Overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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5.2 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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5.3 Checking selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
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5.4 Adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
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6 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

6.1 Selector lever in “P” position and ignition switched on . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.2 Selector lever in “N” position and ignition switched on . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.3 Selector lever in position “Tiptronic” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.4 Ignition and light switched on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.5 Selector lever position indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Contents i
7 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

7.1 Assembly overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
8.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
8.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
8.3 Specified torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
9 Transporting gearbox and securing to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
10 Bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
10.1 Removing and installing bevel box, vehicles with 2.0 l - 100/103/130 kW diesel engine . . 87
10.2 Removing and installing bevel box, vehicles with petrol engine and vehicles with 2.0 l -
110/135 kW diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
10.3 Detaching bevel box from gearbox - gearbox removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
11 Oil and oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
11.1 Renewing oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
11.2 Checking oil level and topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
11.3 Draining and filling oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

1 Currently, no repairs can be made to gears and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

1 Bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.1 Assembly overview - bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2 Overview of fitting locations - seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3 Renewing seals on gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.1 Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.2 Renewing right seal (between gearbox and bevel box) on gearbox . . . . . . . . . . . . . . . . . . 116
4 Renewing seals on bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4.1 Renewing seals on left (between bevel box and gearbox) gen AG
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4.2 Renewing right seal (drive shaft side) . .y.V. . . . . . . . . . . . . . . . . . . . . s.n.ot. g.u . . . . . . . . . . . .
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4.3 Renewing output flange oil seal (bevel ris box removed) . . . . . . . . . . . . . . . . . . n.te.e . . . . . . . .
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4.4 Renewing needle bearing (polygon au bearing) for stub shaft . . . . . . . . . . . . . . . . . r .ac. . . . . .
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5 Checking and topping up gear oil in bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
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5.1 Checking gear oil in bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

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5.2 Filling gear oil in bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

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5.3 Specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

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ii Contents
00 – Technical data
1 Safety information
(VRL010440; Edition 05.2017)
⇒ “1.1 General safety provisions”, page 1
⇒ “1.2 Safety measures when working on vehicles with a start/
stop system”, page 2
⇒ “1.3 Notes on tow-starting/towing”, page 2
⇒ “1.4 Safety precautions when using testers and measuring in‐
struments during a road test”, page 2
1.1 General safety provisions

To prevent personal injury and material damage to the vehicle,
observe the following:
WARNING
Risk of injury and accident by accidental engagement of gear

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

trical and electronic components, observe the following:
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– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

Disconnecting and reconnecting battery .
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1. Safety information 1
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Injury hazard as a result of automatic engine start in vehicles
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♦ In vehicles with the start/stop system activated (identifia‐
ble by an indication in the dash panel insert) the engine
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can start automatically if required.
♦ When working on the vehicle, always make sure that the
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1.3 Notes on tow-starting/towing

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♦ If the vehicle must be towed, the selector lever must be in yri
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no greater than 50 km/h and for a distance not exceeding
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Note
It is not possible to tow-start the engine, e.g. if the battery is too

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

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

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

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

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

Disconnecting and reconnecting battery .
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1. Safety information 3
2 Identification
2.1 Identification of gearbox

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

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

Gearbox
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♦ The gearbox is structured like a manual gearbox. Through op‐
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automatically or manually via the Tiptronic system. There is no
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The feedback for the gearbox concerning the selector lever po‐
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lever cable and the multifunction switch (gear sensor) any more,
as is the case for the automatic gearbox. The information con‐
cerning selector lever positions or shifting operations are trans‐
ferred to the gearbox control unit via a separate control unit in the rrectness of i
l purpos
selector mechanism and the CAN data bus. That is, gears are
shifted without any mechanical cables being involved. Only for
selector lever position “P” the parking lock is engaged mechani‐
nform
ercia
cally via the selector lever cable.

m
Gear change point variations for gradients

com
tion in
r
An additional gear change map automatically selects gear

te o
thi
changes for gradients dependent upon accelerator pedal position

s
iva
do
and driving speed.

r
rp
cum
fo
en
g
• Gear change map for extreme uphill stretches is matched to

n
t.
yi Co
op
engine output. C py
t. rig
gh ht
yri
• Gear change map for extreme downhill stretches is matched
p by
co Vo
by lksw
to the braking effect of the engine. Prote
cted AG.
agen
• If a gear is selected directly via the Tiptronic system, it is also

possible to use the braking effect of the engine in a specific
gear, e.g. when driving down a slope with a trailer attached.
3.2 Rules for cleanliness

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

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

To ensure flawless and successful gearbox repairs, the greatest
care and cleanliness as well as the use of good and proper tools
are essential. Also note the basic rules on safety when performing
repair procedures.
A number of general notes on the individual repair procedures,
which can otherwise be found in the relevant sections of the man‐
ual, are summarised here. They apply for this particular workshop
manual.
wage es n
Guided fault-finding, vehicle self-diagnosis and test instruments
yV
olks ot g
ua
b
ed ran
♦ Before performing repairs to the gearbox, determinehothe
ris cause tee
of the fault as accurately as possible ⇒ Vehicle sdiagnostic
au
t or
ac
tester, Guided Fault Finding , Vehicle Self-Diagnosis
s
ce
e
nl
or Test Instruments .
pt
du
an
itte
y li
Special tool
erm
ab
ility
ot p
For a complete list of special tools used in this workshop manual,
wit
, is n
see ⇒ "Workshop equipment and special tools" .
h re
hole
spec
Gearbox
es, in part or in w
t to the co
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.
rrectness of i
♦ If gearbox covers have been unbolted or gearbox has no fluid,
l purpos
do not run engine or tow vehicle.

♦ First thoroughly clean connecting points and surrounding
nf
ercia
areas and then loosen bolts.
orm
m
♦ When installing the gearbox, ensure that dowel sleeves be‐
atio
om
tween the engine and gearbox are correctly located.
n in
or c
thi
e
Locking devices
t
sd
iva
o
r
rp
cu
♦ Do not overstretch retaining rings.
o
m
f
en
ng
t.
yi
♦ Always renew retaining rings which have been damaged or
Co
op py
overstretched.
t. C rig
gh ht
pyri by
Vo
♦ Retaining rings must locate properly in grooves.
co lksw
by
cted agen
Prote AG.
Dual clutch gearbox oil
The oil quality is of critical importance for the function of the gear‐
box.
Shake oil bottle before opening.
Do not mix additives in oil. Do not fill any other oil.
Oil which has been drained out cannot be filled again.

Oil drain and inspection plug

A plastic overflow pipe (with 8 mm hexagon socket head) is lo‐
cated behind this plug -arrow-. Its length determines the oil level
in the gearbox.
3.4 Gaskets and seals

♦ Renew O-rings, seals and gaskets.
♦ After removing gaskets and seals, always inspect contact sur‐
face of housing or shaft for burrs resulting from removal or for
other signs of damage.
♦ Before installing seals, lightly oil outer diameter and half-fill
space between sealing lips -arrow- with sealing grease -
G 052 128 A1- .
♦ The open side of the oil seals faces toward the side with fluid
filling.
♦ Only use dual clutch gearbox oil. Other
agen
AG. Volubricants
lkswagen AGwill cause
does
problems in function. Volksw not
g y ua
db r
♦ Coat O-rings with dualris clutch gearbox oil to prevent pinching ntee
e a
ho
of rings during assembly.
au
t or
a
ss c
♦ After renewing gaskets, O-rings and seals, check oil level in
ce
le
un
pt
gearbox and top up if necessary ⇒ page 103 .

an
d
itte
y li
rm
ab
pe
3.5 Nuts and bolts

ility
ot
wit
, is n
h re
♦ Loosen and tighten securing bolts and securing nut for covers
hole
spec
and housings diagonally.

es, in part or in w
t to the co
♦ Specified torques given are for unoiled nuts, bolts and screws.
♦ Clean threads of bolts which are to be installed with locking
fluid using a wire brush. Then insert bolts with locking fluid -
rrectness of i
AMV 185 101 A1- .

l purpos
♦ Use a thread chaser to clear residual locking fluid from all

threaded holes into which self-locking bolts are to be screwed.
nform
Otherwise there is a danger of bolts shearing when subse‐

ercia
quently being removed.

m
a
com
tio
♦ Check pitch of thread, to ensure correct thread chaser is used

n in
to clean threads and to ensure the threads are not damaged.

r
te o
thi
s
iva
do
♦ Always renew self-locking bolts and nuts.

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.
3. Repair notes 7
4 Technical data
4.1 Allocation gearbox - engine

⇒ “4.1.1 Tiguan 2008 ►”, page 8
⇒ “4.1.2 Sharan 2016 ►”, page 8
4.1.1 Tiguan 2008 ►

Take account of the gearbox code if spare parts are required for
a repair.
Allocation: gearbox codes for petrol engines
LWT, MYC, NEZ NEZ, NYE, NZT, AG. Volkswagen AG d
RBV agen oes
olksw not
V gu
by
2.0 l - 125/147 kW 2.0 l - 132/155 kW ised ara
nte
TSI TSI ut
hor eo
ra
s a c
s
Allocation: gearbox codes for diesel engines
ce
le
un
pt
an
d
LWS, MYB, MYG, NYD, NZS, RBU QYQ

itte
y li
rm
NYD, NZS, RBU
ab
pe
ility
2.0 l - 100, 103 2.0 l - 130 kW TDI 2.0 l - 110, 135
ot
wit
, is n
kW TDI kW TDI
h re
hole
spec
4.1.2 Sharan 2016 ►
es, in part or in w
t to the co
Take account of the gearbox code if spare parts are required for
a repair.
rrectness of i
Allocation: gearbox codes for diesel engines
l purpos
QYQ, SCY
2.0 l - 110, 135
nform
ercia
kW TDI
m
a
com
4.2 Capacities tion in

r
te o
thi
s
Capacity Dual clutch gearbox 0BH

iva
do
r
rp
cum
Initial filling 7.0 l ± 0.1 l

fo
en
ng
t.
yi
Changing approx. 5.5 litres
Co
op py
♦ Change interval: ⇒ Maintenance manual and/
t. C rig
gh ht
yri
or ⇒ service tables “ELSA” p by
o Vo
by c lksw
cted agen
Prote AG.
Lubricant Dual clutch gearbox oil
The oil is available as a replacement part; part no. ⇒ Electronic
parts catalogue (ETKA) .
Further information in the part number designates the container
size.
Capacity Front bevel box

Initial filling 0.9 l
Changing Filled for life, no change
Lubricant Gear oil
The oil is available as a replacement part; part no. ⇒ Electronic
parts catalogue (ETKA) .

Further information in the part number designates the container

size.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f 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.
4. Technical data 9
5 Electrical components
5.1 Overview of fitting locations - electrical components
1 - Mechatronic unit for dual

clutch gearbox - J743-
❑ Removing and installing
⇒ page 26
2 - Gearbox input speed send‐
er - G182- and oil temperature
sender in multi-plate clutch -
G509-
❑ Both senders are com‐
bined in one component
and can be renewed to‐
gether only.
⇒ page 37
❑ Before removal of the AG. Volkswagen AG d
agen
sender, the mechatronic Volksw
oes
not
gu
unit for dual clutch d bgear‐
y ara
se nte
box - J743- must
thori be re‐ eo
moved ⇒ page
s au 26 . ra
c
s
❑ Discontinued as of gear‐
ce
le
un
pt
box date 06/15

an
d
itte
y li
rm
3 - Selector lever - E313-

ab
pe
ility
❑ For information about

ot
wit
, is n
selector lever, see

h re
⇒ page 47 Selector
hole
spec
mechanism
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.

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

Replacement parts
1 - Retaining ring for dual

clutch end cover
❑ Renew after removal
2 - Retaining ring for dual
clutch
3 - Retaining ring for drive plate
4 - Dual clutch
Caution
The
♦ drive plate has to re‐
main engaged between
the teeth of the outer
plate carrier. n AG. Volkswagen AG do
lkswage es n
o ot g
yV
If♦the drive plate de‐ ir se
d b ua
ran
taches, the plates in the tho tee
or
dual clutch can shift. It ss
au ac
may then not be possible
ce
e
nl
to adjust the clutch cor‐

pt
du
rectly when it is installed. an

itte
y li
erm
ab
ility
ot p
5 - Shims wit
, is n
h re
❑ 10 shims having differ‐
hole
spec
ent »thicknesses«.
es, in part or in w
They are sized in

t to the co
0.05 mm increments.
❑ Thickness of spacer ring
must be determined
rrectness of i
when installing dual

l purpos
clutch.
6 - Dual clutch end cover
nform
ercia

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.
1. Clutch 11
Caution
♦ This figure is intended only to provide an overview of the

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

er
Special tools and workshop equipment required
♦ Clean assembly sleeve - T10459- before using. Do not use a
scratched sleeve.
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
Brief description
The 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.
rrectness of i
Cover and retaining ring must always be renewed. Never install

a new cover with a hammer and never oil the centre seal or touch
l purpos
it with a hand! However, if this should happen, the cover is certain

to leak!
nform
ercia
Removing
m
a
com
ti
The gearbox must be removed for work on cover.

on in
r
te o
thi
– Drain gear oil ⇒ page 105 .

s
iva
do
r
– Remove gearbox ⇒ page 61 .

rp
cum
fo
en
ng
t.
– Secure gearbox to assembly stand ⇒ page 86 .
yi Co
Cop py
t. rig
Often, doubts arise as to whether the filter must be renewed or
gh ht
yri by
not.
op Vo
by c lksw
cted agen
Prote AG.
Note
It is not always necessary to change the oil filter ⇒ page 101 .
12 Rep. gr.30 - Clutch

– Remove filter if necessary ⇒ page 101 .
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
t to the co
– Lever out retaining ring -2- of clutch end cover using screw‐
driver -1- -arrow- and remove.
rrectne
Cover can be levered out with a screwdriver.
ss o
cial p
f
Note
inform
mer
The removed cover and retaining may not be installed again.
atio
om
n
c
i
or
n thi
Install only a »new« cover.
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.
Installing
Caution
Cover and retaining ring must always be renewed.

Never grasp a new cover in centre seal. The centre hole of the
cover must not be touched, oiled or brought into contact with
other materials. Leaks will result.
Never install new covers with a hammer!
1. Clutch 13
– Only handle cover as shown -in this picture-.
Note
There must be no stickers on the inside of the cover. If, however,

stickers are present, remove them carefully.
– The running surface on the end of the shaft of the clutch

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

installing:
– Clean assembly sleeve - T10459- “before using”. Do not use

a scratched sleeve. agen
AG. Volkswagen AG d
o
ksw es n
Vol ot g
– Set sleeve on a flat surface. ed by ua
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
– Guide cover horizontally and evenly over entire sleeve

-as shown in this figure-. This will bring the sealing lip into in‐
stallation position.
rrectness of i
– Remove sleeve upwards out of cover and set sleeve on end

l purpos
of clutch shaft.
– Moisten outer seal of cover with oil.
nf
ercia
orm
m
atio
Caution
om
n in
or c
thi
Moisten only the outer seal of the cover with oil. Oiling the inner
te
sd
a
seal will always cause leaks.

iv
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.

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

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

-screwdriver- until »new« retaining ring can be installed.
– Install new retaining ring.
n AG. Volkswagen AG
– Do not remove
olks
wbush
age until retaining ring
does is installed.
no
V t gu
by ara
– Installing
ris
ed gearbox ⇒ page 82 nte
tho eo
– sTop
s a up gear oil ⇒ page 105 .
u ra
c
ce
e
nl
pt
du
an
WARNING
itte
y li
erm
ab
ility
Do not start engine if there is no oil in gearbox.

ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1.3 Removing dual clutch

rrectness of i

l purpos
♦ 2 x hooks - 3438-
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.
1. Clutch 15
♦ Puller - T10055-
♦ Puller - T10525-
Brief description olkswage es n
ot g
byV ua
• The axial play of the clutch is readjusted during installation
ir se
d ran
tee
procedure. utho
or
a ac
ss
• To remove or install clutch, gearbox must be securely attached
ce
le
un
to an assembly stand in vertical position ⇒ page 86 . Only
pt
an
d
this way is it possible later to adjust axial play of the clutch

itte
y li
rm
without error.
ab
pe
ility
ot
Removing
wit
, is n
h re
– Remove clutch end cover ⇒ page 12 .
hole
spec
es, in part or in w
Important! Installation location of drive plate

t to the co
– Check that marking on drive plate -arrow- aligns with the mark‐
ing on the outer plate carrier.
rrectness of i
If there is no marking:
l purpos
– Mark installation position of drive plate relative to periphery of

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

a
com
tio
marked position.
n in
r
te o
thi
s
iva
do
r
Note
rp
cum
fo
en
ng
t.
yi Co
The retaining ring is renewed together with the clutch. If the clutch Cop py
which is removed is reinstalled, the securing ring is to be used
t. rig
gh ht
yri by
again as well. cop Vo
by lksw
cted agen
Prote AG.

– Lever out retaining ring -2- of drive plate using screwdriver

-1- -arrow-.
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
– Apply puller - T10525- together with puller - T10055- on
h re
ole,
splines and carefully pull drive plate off its seat -arrows-.
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
co lksw
by
cted agen
Prote
– Remove retaining ring -arrow- and save it for now.
AG.
Note
Do not dispose of the retaining ring yet because it will be needed

to measure axial clearance.
1. Clutch 17
– Remove shim -arrow-. AG. Volkswagen AG d

agen oes
olksw not
V gu
by
Caution rised ara
nte
ho eo
aut ra
Carefully remove the dual clutch. Take care sthat no parts fall
s c
out. Therefore, do not turn the clutch over!
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
– Engage 2 hooks - 3438- on opposite sides of clutch -arrow-.
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
– Remove dual clutch using hooks - 3438- . Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1.4 Installing dual clutch

♦ Universal dial gauge holder - VW 387-

♦ Dial gauge - VAS 6079-
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
♦ Retaining pins - T10524-
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
♦ Thrust piece - T10526-

rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Caution
♦ The drive plate has to remain engaged between the teeth

of the outer plate carrier.
♦ If the drive plate detaches, the plates in the dual clutch can
shift. It may then not be possible to adjust the clutch cor‐
rectly when it is installed.
♦ Do not lift (not even slightly) or remove plate carrier! The
plates could turn.
Brief description
• To remove or install the clutch, the gearbox must be securely
attached to an assembly stand in vertical position.
• The large plate carrier goes through all plates inside the clutch.
It must not slip out of the lowest plate.
1. Clutch 19
Installing
AG. Volkswagen AG d
– Take great care when removing the dual clutch from its pack‐lkswagen oes
not
age. db
yV
o gu
ara
e nte
ris
– Turn piston rings by hand. They must move freelyuand
tho must eo
ra
not bind. ss a c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Ensure that piston rings -1-, -2-, -3- and -4- are seated cor‐
rectly. The ring butts -arrows- of piston rings -1- and -3- should
rrectness of i
align.
l purpos
– The ring butts -arrows- of piston rings -2- and -4- should align
and be offset 180° to the ring butts of piston rings -1- and -3-.
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
Important! Position of drive plate gh ht
pyri by
Vo
co lksw
by
– Before installing, check if there is a marking -arrow- on dual Prote
cted AG.
agen
clutch.
– If there is no marking, use a permanent marker to make a col‐
our marking on the drive plate and one the outer plate carrier.
– Insert retaining pin - T10524- .

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

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

– If necessary, insert clutch by turning slightly.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
The dual clutch is properly fitted if there is horalmost
is no play in the nte
eo
retaining pin - T10524- . s aut ra
c
s
ce
e
nl
pt
du
an
Note
itte
y li
erm
ab
ility
ot p
♦ The retaining pin remains inserted until the clutch end cover
wit
is installed.
, is n
h re
hole
♦ The dual clutch must now not be rotated any more, as this can
spec
shift the position of the retaining pin - T10524- .
es, in part or in w
t to the co
rrectness of i
– Lever out retaining ring -2- of drive plate using screwdriver
l purpos
-1- -arrow-.
nf
ercia
o
Note
rm
m
atio
om
This retaining ring will be used again. Do not dispose of it.
n in
or c
thi
te
sd
iva
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m
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ng
t.
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Clutch 21
– Apply puller - T10525- together with puller - T10055- on

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

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

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

• The retaining pin - T10524- remains installed!
AG. Volkswagen AG d
agen oes
olksw not
– Temporarily install “old” retaining ring -arrow-. d by V gu
ara
rise nte
Before this ring is finally disposed of, 3 measurements
autho
must be eo
ra
made. ss c
ce
e
nl
First measurement (axial play of shaft)
pt
du
an
itte
y li
– Screw universal dial gauge - VW 387- to gearbox flange.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Set -tip of dial gauge- on input shaft.
rrectness of i
– Set -dial gauge- to 0 with preload.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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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.

– Lift dual clutch with force -in direction of arrow- to stop using
hooks - 3438- and note measurement.
– Call this value “A”.
Note
This value will be needed later for the check measurement so

save value “A” until the last measurement has been performed.
Second measurement
– Set tip of dial gauge -on hub of large plate carrier-.
Note
Tip must not sit on retaining ring.

. Volkswagen AG
gen AG does
– Set -dial gauge- Vto
olk0
swwith
a
preload again. not
y gu
db ara
– Lift dual clutch
or
ise with force to stop and note measurement. nte
eo
h
ut ra
– Call this
ss value “B”.
a c
ce
e
nl
Now calculate which shim must be fitted:

pt
du
an
itte
y li
– Use this formula:

erm
ab
ility
ot p
Value “B” minus value “A” minus 0.11 = thickness of shim to

wit
, is n
be fitted.
h re
hole
spec
– Note result.
es, in part or in w
t to the co
The shims are sized in 0.05 mm increments.

– Measure the shims and determine which one is closest to the
result.
rrectness of i
l purpos
WARNING
nf
ercia
Always use the next-largest shim, never the next-smallest.

orm
m
atio
om
n in
c
Example:
or
thi
te
sd
iva
Calculated dimension for shim New shim

o
r
rp
cu
o
m
f
1.28 mm 1.3 mm
en
ng
t.
yi Co
op
1.26 mm 1.3 mm
C py
ht. rig
rig ht
py by
co Vo
by lksw
– Remove old retaining ring -arrow-. cted agen
Prote AG.
Note
Do not dispose of ring yet; it will be needed once more.
1. Clutch 23
7-speed dual clutch gearbox 0BH. V-oEdition
lkswage 05.2017
AG n AG d
agen oes
olksw not
– Fit calculated shim. db
yV gu
ara
rise nte
Third measurement (checktho measurement) eo
s au ra
c
s
To make sure that the shim is correct, a test measurement must
ce
e
nl
still be carried out. Proceed as follows:
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 old retaining ring -arrow- once more.
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
yri by
– Set tip of dial gauge -on hub of large plate carrier-.
cop Vo
by lksw
cted agen
Prote AG.
Note
Set the tip of the dial gauge on the shim -1-.
– Set -dial gauge- to 0 with preload again.

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

– Fit drive plate into dual clutch.

wage
es ks not
Vol g
• When installing, echeck
db
y if marking on drive plate is aligned
ua with
ran
marking on outer
thoris plate carrier -arrows-. If the markings were
tee
or
subsequently
s au make, align these. ac
s
ce
le
– A second mechanic must hold retaining pin - T10524- in its

un
pt
place and press outwards slightly.
an
d
itte
y li
rm
ab
– Carefully drive the drive plate onto its seat using thrust piece
pe
ility
- T10426- and a plastic mallet.
ot
wit
, is n
h re
– Install drive plate retaining ring.
hole
spec
– Starting at the opening, press retaining ring in clockwise di‐
es, in part or in w
t to the co
rection into its fitting position.
• The retaining ring must be fully engaged.
rrectness of i
– Use screwdriver to check that retaining ring is correctly seated
and engaged.
l purpos
– Now remove retaining pin - T10524- from between dual clutch

and housing.
nform
ercia
– Install clutch end cover ⇒ page 12 .

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.
1. Clutch 25
34 – Controls, housing
1 Mechatronic unit
⇒ “1.1 Removing and installing mechatronic unit for dual clutch
gearbox J743 (gearbox installed)”, page 26
gearbox J743 (gearbox removed)”, page 31
⇒ “1.3 Removing and installing gearbox input speed sender G182
and oil temperature sender in multi-plate clutch G509 up to gear‐
box date 05/15”, page 37
1.1 Removing and installing mechatronic

unit for dual clutch gearbox - J743-
(gearbox installed)
gearbox J743 (gearbox removed)”, page 31
♦ Torque wrench - V.A.G 1331-
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
♦ Up to gearbox date 05/15 release tool - T10465-

rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
yi
Always make sure that no dirt can enter an »open« gearbox.
Co
Cop py
t. rig
gh
In particular, dirt entering an »exposed« mechatronic unit for dual
ht
pyri by
Vo
o
clutch gearbox - J743- can lead to gearbox failure. by c lksw
cted agen
Prote AG.
Please also refer to the notes on the oil filter change regarding
»dirty oil« ⇒ page 101 .
Remove mechatronic unit.
– Move selector lever to position “P”.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation; Assembly overview - noise in‐
sulation
26 Rep. gr.34 - Controls, housing

– Remove connecting hose between charge air cooler and

charge air pipe ⇒ Rep. gr. 21 ; Removing and installing parts
of charge air cooling .
Note lks wage es n
o ot g
byV ua
d ran
ir se
It is possible that parts having nothing
tho to do with the mechatronic tee
or
unit must be removed. This depends
ss
au
on the vehicle's equipment. ac
This will create enough space to remove the mechatronic unit.
ce
le
un
pt
an
d
itte
y li
– Unbolt wiring retainer from front of »large« gearbox cover (2
rm
ab
nuts M6).
pe
ility
ot
wit
, is n
h re
– Release mechatronic unit connector by turning in
hole
-direction of arrow- and pull off connector.
spec
es, in part or in w
t to the co
– Raise lines near cover and tie.
– Place used oil collection and extraction unit - V.A.G 1782- be‐
low gearbox.
rrectness of i
– Drain oil ⇒ page 105 .
l purpos
nform
mercia
a
com
tion in
r
te o
thi
– Remove securing clip -3-.
s
iva
do
r
rp
cum
– Unscrew bolts -1- diagonally and remove.
fo
en
ng
t.
yi Co
– Remove cover -2- with seal. t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
Note
cted agen
Prote AG.
Always renew bolts, securing clips and the cover with seal.
Before touching mechatronic unit, touch an earthed object again.
1. Mechatronic unit 27
– If fitted, release connector -1- of gearbox input speed sender

- G182- and oil temperature sender in multi-plate clutch -
G509- using release tool - T10465- .
– Remove bolts -arrows- diagonally.

All 9 bolts have same length and are not allowed to be reused.
– Remove mechatronic unit -1- carefully.

agen
AG. Volkswagen AG d
w oes
olks not
byV gu
ara
d
Caution orise nte
eo
th
au ra
c
• Lift or ss mechatronic
put down unit only on housing and on
ce
e
solenoid valves.
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.

Lay mechatronic unit to side properly.

– Put down mechatronic unit so that sensors -arrows- are point‐
ing upwards.
Install mechatronic unit.
Install in reverse order of removal. During this procedure, observe
the following:
WARNING
Before installing the mechatronic unit, clean the sealing sur‐

face on the gearbox housing thoroughly
agen
AG. Vowithout using
lkswagen AG
doecleaning
agents. Always make sure olksw no dirt can get into the
that inside.
s no
t gu
yV b ara
ed nte
oris e
th or
au ac
ss
– Before installation, check that »sender« -1- is installed
ce
e
nl
⇒ page 37 .
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
Before touching mechatronic unit, touch an earthed object again. nf

ercia
orm
m
Caution
atio
om
n in
or c
• Lift or put down mechatronic unit only on housing and on

thi
te
solenoid valves.
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.
– Carefully insert mechatronic unit -1- into gearbox.

– Screw in new bolts -arrows- diagonally until finger-tight.
– Tighten bolts in specified sequence to 8 Nm + 45°.
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
– Push on connector -1-, if fitted, and engage.

nform
ercia
– After this, check that fastener -2- is not damaged.

m
at
om
io
Caution
n
c
in t
or
his
ate
• Work with great care. The fastener of the connector -2-

do
priv
can break. If this has happened, the connector will no

um
for
en
g
longer hold and the damaged part, e.g. mechatronic unit

n
t.
yi Co
for dual clutch gearbox - J743- must be renewed. Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
Continuation for all:
agen
Prote AG.

– Renew seal -arrow-.

A new mechatronic unit already has a new oil seal.
– Lubricate seal with ⇒ DSG oil.
– Set new cover with seal -2- in place and tighten with new bolts
-1- diagonally in several stages to 10 Nm + 45°.
– Install new securing
agenclip -3-.
AG. Volkswagen AG d
oe w s no
olks t
– Attach wire
ed
byretainer to cover and tighten nutsguto
V
ara10 Nm.
is nte
or
– Push au
thon connector for mechatronic unit for dual clutch
eo
r agearbox
- J743-
ss and engage lock by turning. c
ce
e
nl
– Install connecting hose between charge air cooler and charge pt

du
an
itte
air pipe ⇒ Rep. gr. 21 ; Removing and installing parts of y li

erm
ab
charge air cooling . ility
ot p
wit
, is n
h re
hole
spec
– Do not start engine!

es, in part or in w
t to the co
– Fill with oil ⇒ page 105 .

– Install noise insulation ⇒ General body repairs, exterior; Rep.
rrectness of i
gr. 50 ; Noise insulation; Assembly overview - noise insulation

l purpos
– Conduct basic adjustment of mechatronic unit for dual clutch

gearbox - J743- .
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.
1.2 Removing and installing mechatronic

unit for dual clutch gearbox - J743-
(gearbox removed)
gearbox J743 (gearbox installed)”, page 26
♦ Up to gearbox date 05/15 release tool - T10465-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
is nte
Always make sure that no dirt can enter an »open«
hor gearbox. eo
aut ra
s c
In particular, dirt entering an »exposed« mechatronic
s unit for dual
ce
le
clutch gearbox - J743- can lead to gearbox failure.

un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
Remove mechatronic unit.

h re
ole,
– Drain oil ⇒ page 105 . spec

t to the co
– Remove securing clip -3-.
Always renew securing clip.
rrectne
– Unscrew bolts -1- diagonally and remove.

– Remove cover -2- with seal.
ss o
cial p
f inform
Note
mer
atio
om
Always renew bolts, securing clips and the cover with seal.
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
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
– If fitted, release connector -1- of gearbox input speed sender
es, in part or in w
- G182- and oil temperature sender in multi-plate clutch -
t to the co
G509- using release tool - T10465- .
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
c
– Remove bolts -arrows- diagonally. um
fo
en
ng
t.
yi
All 9 bolts have same length and are not allowed to be reused.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove mechatronic unit -1- carefully.
Caution

solenoid valves. 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
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
Lay mechatronic unit to side properly.
rrectness of i
– Put down mechatronic unit so that sensors -arrows- are point‐
l purpos
ing upwards.
Install mechatronic unit.
nform
ercia

m
a
com
the following:
tion in
r
te o
thi
s
WARNING
iva
do
r
rp
cum
fo
Before installing the mechatronic unit, clean the sealing sur‐

en
ng
t.
yi Co
face on the gearbox housing thoroughly without using cleaning Cop py
agents. Always make sure that no dirt can get into the inside.
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Before installation, check that »sender« -1- is installed

⇒ page 37 .

Caution

solenoid valves.
– Carefully insert mechatronic unit -1- into gearbox.

– Screw in new bolts -arrows- diagonally until finger-tight. agen
AG. Volkswagen AG d
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
t to the co
rrectness o
cial p
f in
– Tighten bolts in specified sequence to 8 Nm + 45°.
form
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.
– Push on connector -1-, if fitted, and engage.

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

can break. If this has happened, the connector will no
longer hold and the mechatronic unit for dual clutch gear‐
box - J743- must be renewed.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
or
– Renew seal -arrow-. ss
au ac
ce
e
A new mechatronic unit already has a new oil seal.

nl
pt
du
an
itte
y li
– Lubricate seal with ⇒ DSG oil.
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
– Set new cover -2- in place and tighten with new bolts -1- di‐
agonally in several stages to 10 Nm + 45°.
nform
ercia
– Install new securing clip -3-.

m
at
om
After installation of gearbox

ion
c
in t
or
– Fill with oil ⇒ page 105 .

his
ate
do
riv
– Conduct basic adjustment of mechatronic unit for dual clutch

p
cum
or
gearbox - J743- .
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1.3 Removing and installing gearbox input

speed sender - G182- and oil tempera‐
ture sender in multi-plate clutch - G509-
up to gearbox date 05/15
Note
♦ As of gearbox date 06/15, the gearbox input speed sender -

G182- and the oil temperature sender in multi-plate clutch -
G509- have been discontinued.
♦ If a sender is fitted, a sender must be reinstalled after it has
been removed.
♦ The following procedure applies only to gearboxes in which a
sender is fitted.
Brief description
Both senders are combined in one component and can be re‐
newed together only. They are in the gearbox near the multi-
clutch. Before removal, the mechatronic unit for dual clutch
gearbox - J743- must be removed.
Removing
– Remove mechatronic unit for dual clutch gearbox - J743-
⇒ page 26 .
Do not pull on line!
– Unscrew and remove bolt -2- and pull out sender -1-.
Installing
the following:
AG. Volkswagen AG d
agen
Reinstall »old« sender only if: Volksw
oes
not
by gu
d ara
• The sender has no defect orise nte
th eo
u ra
• The cable was not pulled on when
ss a it was removed c
ce
e
nl
– Moisten sender with dual clutch gearbox oil and install.

pt
du
an
itte
y li
– Tighten bolt -2- to 10 Nm.

erm
ab
ility
ot p
– Install mechatronic unit for dual clutch gearbox - J743-

wit
, is n
⇒ page 26 .
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
37
AG.
1. Mechatronic unit
2 Removing and installing gear oil cool‐

er
⇒ “2.1 Renewing bleeder”, page 40
♦ Hose clamps to 25 mm - 3094-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
Removing
yi Co
Cop py
t. rig
– Move selector lever to position “P”. gh ht
pyri by
Vo
co lksw
by
– Remove air filter housing. Prote
cted AG.
agen
♦ Petrol engine: ⇒ Rep. gr. 24 ; Air filter; Removing and instal‐

ling air filter housing
♦ Diesel engine: ⇒ Rep. gr. 23 ; Air filter; Removing and instal‐
– Remove battery with battery tray ⇒ Rep. gr. 27 ; Battery;
Removing and installing battery .
– Lay lint-free cloths on gear oil cooler and gearbox to catch
escaping coolant.
– Clamp off coolant hoses using hose clamps -3094- and re‐
move from cooler.

– Remove bolts -A- and remove gear oil cooler -B-.
Caution
No coolant must be allowed to drip into gearbox!
Installing
the following:
wage es n
– Renew O-rings -C-. yV
olks ot g
ua
b
ed ran
– Set gear oil cooler -B- in place. When doing tthis,
hor note O-rings
is tee
or
-C-. au ac
ss
ce
– Screw in new bolts -A- and tighten to 20 Nm + 45°.
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
– Attach coolant hoses to gear oil cooler and remove hose
n
c
in t
r
clamps -3094- .
o
his
ate
do
riv
Continue installation in reverse order of removal.

p
cum
for
– Install battery with battery tray ⇒ Rep. gr. 27 ; Battery; Re‐

en
ng
t.
yi Co
moving and installing battery . t. Cop py
rig
gh ht
– Install air filter housing. yri
p by
co Vo
by lksw
cted
agen
Prote AG.
– Check coolant level and top up with coolant as needed ⇒ Rep.
gr. 19 ; Removing and installing parts of cooling system .
– Checking and adjusting oil level ⇒ page 103 .
2. Removing and installing gear oil cooler 39

2.1 Renewing bleeder

Removing
– Pull off cap -arrow- by hand.
AG. Volkswagen AG d
agen oes
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– Insert screwdriver -1- between collar of gearbox and breather
ce
e
nl
pt
du
pipe -2-.
an
itte
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erm
ab
– Pry off breather pipe -2- with screwdriver -1-.
ility
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Installing
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hole
– Push on breather pipe -2- powerfully by hand.
spec
es, in part or in w
Breather pipe must be heard and felt to engage.
t to the co
– Put on cap.
rrectness of i
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nf
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3 Emergency release of selector lever

♦ Wedges - T10383/1-
Do not remove knob.

– Depress brake pedal or set handbrake.
– Using wedge - T10383- , carefully lever gear lever gaiter off
centre console insert -arrows-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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pt
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ility
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– Press yellow plastic part -arrow- from above and hold in this
wit
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position.
h re
hole
spec
Lever can now be moved from position »P«.
es, in part or in w
t to the co
rrectness of i
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nf
ercia
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or c
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3. Emergency release of selector lever 41

4 Removing and installing selector lev‐

er handle
⇒ “4.1 Removing and installing handle”, page 42
⇒ “4.2 Moving push button in the handle to installation position”,
page 45
4.1 Removing and installing handle

♦ Handle with clip: hose clip pliers - V.A.G 1275-
AG. Volkswagen AG d
agen oes
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es, in part or in w
t to the co
♦ Wedges - T10383/1-
rrectness of i
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nform
mercia
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tion in
r
te o
thi
s
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do
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Brief description
t. C rig
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Vo
o
Handle is removed together with selector cover. by c lksw
cted agen
Prote AG.
Removing
– Shift selector lever to position “D”.
The push button -arrow- does not need to be pulled out by hand.
Push button engages automatically in installation position when
handle is pulled off.

– Using wedge - T10383- , carefully lever gear lever gaiter off

centre console insert -arrows-.
– Separate electrical connector.
Handle with locking sleeve:
– To release handle, slide

n AGplastic
. Volkswpart under
agen AG do handle in direction
of -arrow- wage es n
olks ot
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s au ra
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nl
pt
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
Handle with clamp:

– Cut open clamp -arrow- under boot using side cutters.
rrectness of i
Continuation for all handles:

l purpos
– Pull handle upwards off selector lever without pressing push

button.
nf
ercia
orm
m
atio
om
Note
n in
or c
thi
te
sd
a
Do not press button again after removal as it will no longer be

iv
o
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cu
possible to install the handle.

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t.
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op
Installing C py
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Install in reverse order of removal, observing the following:
cop Vo
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• Selector lever is in position “D”.
AG.
4. Removing and installing selector lever handle 43

Note
♦ There is a chance that the button could be pressed into the

handle. Never install a handle with the button pressed in.
♦ Move push button to installation position ⇒ page 45 .
♦ New handle is supplied with installation guard. Do not remove
guard until just before installing. To remove, pull out
-in direction of arrow-.
Handle with locking sleeve:

– Push handle onto selector lever as far as stop and lock.
Volkswagen AG
– To lock, push sleeve downwards opposite direction ofswarrow.
agen
AG. does
olk not
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Handle with clamp: edb ara
nte
ris
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au ra
c
ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
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Cop py
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rig ht
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44
by lksw
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Rep. gr.34 - Controls, housing Prote AG.
– Push on handle with new clamp -arrow- to stop. Do not tighten

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

after being pressed. If this happens, pull handle off again and
move push button to installation position again ⇒ page 45 . Then
fit the handle again.
Handle with clamp:

– If the press button moves back to its start position, the clamp
can be tightened using the hose clip pliers - V.A.G 1275- .
– Connect electrical connector.
– Clip in selector cover.
4.2 Moving push button in the handle to in‐

stallation position
Special tools and workshop equipment required AG. Volkswagen AG d
agen oes
lksw not
♦ Release tool - T10534- d by
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spec
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t to the co
rrectness of i
If the button was pressed by mistake, the installation position can
be restored.
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There are 2 ways of moving the push button into the installation
position, »with« and »without« installation guard. Both of them are
nform
ercia
described here.
m
a
com
Placing handle »with« release tool - T10534- in installation posi‐

ion in
tion:
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te o
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s
iva
Instead of the release tool - T10534- , the installation guard which

do
r
rp
is delivered with new handles may also be used.

cum
fo
en
ng
t.
When using the installation guard, make sure that it has an eyelet
yi Co
op
-arrow- at the front. Other types of installation guard are not suit‐
C py
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able.
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Prote AG.
4. Removing and installing selector lever handle 45

– Holding down push button, completely push in release tool -

T10534- installation guard with eyelet -arrow-. The installation
guard latches in place while doing so.
– Now, release push button. When the installation guard is
pulled out, the push button engages in installation position.
Placing handle »without« release tool - T10534- or installation
guard in installation position:
– Carefully unclip handle trim -A- upwards.
lkswage es n
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d ran
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– Using a screwdriver,
ss
a press the small lever -1- for the tie rod ac
into the groove -2-. This action presses the push button -3- into
ce
le
un
pt
installation position.
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-I- = button pressed in

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-II- = button in installation position

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spec
Note
t to the co
♦ Press the lever only into the groove and no further.

♦ Do not clip the handle trim onto selector mechanism until the
rrectne
handle has been fitted. This makes it possible to check wheth‐

er the small lever engages in the pull rod when the button is
ss
pressed.
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
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pr
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Prote AG.

AG. Volkswagen AG d
agen 7-speed dualoeclutch gearbox
0BH - Edition 05.2017
olksw s no
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5 Selector mechanism ss au ra
c
ce
le
⇒ “5.1 Overview - selector mechanism”, page 47
un
pt
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d
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⇒ “5.2 Removing and installing selector mechanism”, page 48
rm
ab
pe
ility
⇒ “5.3 Checking selector lever cable”, page 51
ot
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⇒ “5.4 Adjusting selector lever cable”, page 52
hole
spec
es, in part or in w
t to the co
WARNING
Before working on vehicle with engine running, move selector
rrectness of i
lever into position “P” and apply handbrake.
l purpos
5.1 Overview - selector mechanism
nform
mercia
a
com
t
1 - Handle with selector cover
ion in
r
❑ Do not remove handle

te o
thi
without reason. For
s
iva
do
r
emergency release, on‐

rp
cum
fo
ly the cover needs to be
en
ng
t.
unclipped ⇒ page 41 .
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rig
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⇒ page 42 cop Vo
by lksw
cted agen
Prote
2 - Selector lever and selector
AG.
mechanism with selector lever

cable
❑ With selector lever lock
solenoid - N110-
❑ Selector mechanism
and selector lever cable
are not allowed to be
separated from one an‐
other. Both are removed
together.
⇒ page 48
❑ Do not grease Bowden
cable
❑ Checking ⇒ page 51
❑ Adjusting ⇒ page 52
3 - Bolt
❑ 8 Nm
4 - Hexagon flange nut
❑ 8 Nm
❑ Qty. 4
5 - Selector housing
5. Selector mechanism 47
5.2 Removing and installing selector mech‐

anism
⇒ “5.2.1 Removing and installing selector mechanism with selec‐
tor housing”, page 48
⇒ “5.2.2 Removing and installing selector mechanism without se‐
lector housing”, page 50
5.2.1 Removing and installing selector mech‐

anism with selector housing
Brief description
Selector mechanism and selector lever cable are not allowed to
be separated from one another. Both are removed together with
the selector housing.
In the interior, the centre console must be removed.
The heat shield beneath the vehicle must be removed.
The selector mechanism with selector lever cable can be re‐
moved and installed separately without removing and installing
the selector housing ⇒ page 50 .
Note
Following installation, cable must be checked for ease of move‐

ment and be adjusted.
Removing
– Remove selector lever handle ⇒ page 42 .
– Remove centre console ⇒ Rep. gr. 68 .
n AG. Volkswagen A
– Separate electrical connector from selector
olks
wagmechanism
e
to ve‐G does no
hicle wiring harness. db
y V t gu
ar
e an
ris tee
– Remove air filter housing. tho or
au ac
ss
ce
le
un

pt
an
d
itte
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rm
ab
pe

ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
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iva
do
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cum
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en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

– Pry selector lever cable -arrow- off lever using an open-ended

spanner.
Caution
Locks on selector lever cable break off very easily. If a locking

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

gether -arrows- and remove selector lever cable upwards out
of cable support bracket.
– Do not bend or kink cable.
– Install centre tunnel heat shield below selector mechanism ⇒
General body repairs, exterior; Rep. gr. 66 ; Mouldings/trims/
extensions; Removing and installing floor heat shield .
Note
To remove selector mechanism, a 2nd mechanic is required un‐

der the vehicle. olkswage es n
ot
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db ara
ir se nte
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– Remove nuts
aut -arrows- inside vehicle. ra
c
ss
– If fitted, remove bracket -A-.
ce
e
nl
pt
du
an
itte
– Remove selector mechanism -B- together with selector lever

y li
erm
ab
cable and selector housing downwards.

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Installing
wit
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hole
Install in reverse order of removal.

spec
es, in part or in w
– Before putting cable on selector shaft, position selector lever

t to the co
on selector mechanism forwards in direction to travel to posi‐

tion “P”.
rrectness of i
– Also move selector shaft on gearbox to position “P”. To do this,

push lever opposite to driving direction to rear stop.
l purpos
– Before ball head of cable is placed on selector shaft: check

selector lever cable ⇒ page 51 .
nf
ercia
orm
– Install centre tunnel heat shield below selector mechanism ⇒

m
atio
m
General body repairs, exterior; Rep. gr. 66 ; Mouldings/trims/

o
n in
c
extensions; Removing and installing floor heat shield .

or
thi
te
sd
a
– Install centre console ⇒ Rep. gr. 68 .

iv
o
r
rp
cu
o
– Install selector lever handle ⇒ page 42 .

f
en
ng
t.
yi Co
op
– Adjust selector lever cable after installing ⇒ page 52 . C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
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Sharan 2016 by V ➤ , Tiguan 2008 ➤
ol
gu
ara
d
7-speed orise dual clutch gearbox 0BH - Edition 05.2017 nte
eo
th
au ra
s c
5.2.2 Removing and installing selector mech‐
s
ce
e
nl
pt
du
anism without selector housing
an
itte
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erm
ab
Brief description
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wit
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Selector mechanism and selector lever cable are not allowed to
h re
be separated from one another. Both are removed together.
hole
spec
es, in part or in w
In the interior, the centre console must be removed.
t to the co
A cord must be attached to the Bowden cable before it is removed.
The cord is needed to guide the Bowden cable between the tunnel
and the heat shield.
rrectness of i
The selector mechanism with selector lever cable can also be
l purpos
removed and installed with the selector housing ⇒ page 48 .

Removing
nf
ercia
orm
m
– Remove selector lever handle ⇒ page 42 .
atio
om
n in
c
– Remove centre console ⇒ General body repairs, interior; Rep.

or
thi
gr. 68 ; Centre console; Removing and installing centre con‐
te
sd
iva
sole .
o
r
rp
cu
o
m
f
– Separate electrical connector from selector mechanism to ve‐ en

ng
t.
yi
hicle wiring harness.
Co
Cop py
t. rig
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– Remove air filter housing.
ht
pyri by
Vo
co lksw
by
cted
agen
Prote AG.

spanner.
Caution


– Then a long cord must be attached to the end of the Bowden
cable. The cord is needed to guide the Bowden cable between
the tunnel and heat shield during installation.
– Remove 4 bolts.

AG. Volkswagen AG d
agen oes
olksw not
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ss a 7-speed dual clutch c gearbox 0BH - Edition 05.2017
ce
le
un
pt
– Carefully pull selector mechanism with Bowden cable out of
an
d
itte
y li
the centre tunnel. Ensure that the cord remains accessible
erm
ab
from the engine compartment after being pulled by the Bow‐
ility
ot p
den cable.
wit
is n
h re
– Remove cord from Bowden cable.
ole,
spec
Installing
t to the co
Install in reverse order of removal, observing the following:
A second mechanic is needed to guide Bowden cable from pas‐
rrectne
senger compartment into engine compartment.
ss o
Note
cial p
f inform
mer
♦ Do not bend or kink gear selector cable.
atio
om
n
♦ Do not grease selector lever cable.
c
i
or
n thi
te
sd
va
– Attach Bowden cable to cord which was drawn into the pas‐
i
o
pr
cum
r
senger compartment during removal.

fo
en
ng
t.
yi Co
– Carefully guide selector mechanism with Bowden cable Cop py
t. rig
through opening in centre tunnel. opyri
gh by
Vo
ht
c lksw
– Have the second mechanic pull cord with Bowden cable
by
cted agen
Prote
through tunnel from engine compartment until Bowden cable
AG.
can be attached to support bracket.

– Remove cord from Bowden cable.
– Secure selector mechanism to selector housing using 4 bolts.

Specified torque: 8 Nm
– Before fitting cable on selector shaft, position selector lever in
vehicle forwards to position “P”.
– Also move gearbox selector lever to position “P”. To do this,
– Before ball head of cable is placed on selector shaft: check
selector lever cable ⇒ page 51 .
– Install centre console ⇒ Rep. gr. 68 .
– Install selector lever handle ⇒ page 42 .
– Check selector lever cable after installing ⇒ page 51 .
5.3 Checking selector lever cable

Brief description
To check ease of movement of selector lever cable, it must be
removed from the gearbox and the free end must be placed so
that it does not bump against anything.
Then move selector lever and reinstall the cable.
Then the selector lever cable must be adjusted ⇒ page 52 .
Do not grease cable
Check
– Switch selector lever to »P« position.

spanner.
Caution

G. Volkswagen AG d
– Carefully push locking mechanisms of selector lever cable to‐ lkswagen A oes
not
gether -arrows- and remove selector lever cable upwardsdoutby
Vo gu
ara
of cable support bracket. or
ise nte
th eo
– Do not bend or kink cable. au ra
c
ss
ce
e
nl
– Shift selector lever several times from position »P« to »S« and
pt
du
an
back to »P«.
itte
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erm
ab
• Selector lever must move easily.
ility
ot p
wit
, is n
– Reinstall cable.
h re
hole
spec
– Adjust selector lever cable. ⇒ page 52
es, in part or in w
t to the co
5.4 Adjusting selector lever cable
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.

The selector lever cable must be adjusted if

Volkswa AG. gen AG
agen do
♦ The selector lever cable
Vohas
lksw been removed from the
es n
gearbox.
ot g
by ua
ed ra
♦ The engine and/or
ho
ris gearbox has been removed and installed.
nte
e t or
au ac
♦ The cable with
ss the selector mechanism has been removed and
installed.
ce
le
un
pt
an
d
itte
♦ The position of the engine and gearbox is shifted, for example
y li
erm
ab
to install it free of tension.
ility
ot p
Adjusting:
wit
is n
h re
ole,
– Move selector lever in vehicle to “P” position.
spec
– Selector shaft on gearbox is also in position “P”. To check,
t to the co
rrectne
Note
ss
Raise vehicle, to be sure that the gearbox is in “P” (parking lock
o
cial p
f
engaged). It should not be possible to turn both front wheels to‐
inform
gether in the same direction.
mer
atio
om
n
c
i
– Loosen bolt -2- of the Bowden cable -1-.
or
n thi
te
sd
va
– Gently push knob of selector lever forwards and backwards

i
o
pr
cum
but under no circumstances must you shift out of “P”.
r
fo
en
ng
t.
yi
In this way the ⇒ inner cable of the Bowden cable finds it optimal
Co
Cop py
position.
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gh ht
pyri by
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– Tighten bolt -2- to 15 Nm.
c by lksw
cted agen
Prote AG.
6 Checking selector mechanism

lksw
agen
AG. Volkswagen AG d
oes
n o ot g
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⇒ “6.1 Selector lever in P positionisand
ed ignition switched on”, page
b ran
54 ut
hor tee
or
sa ac
⇒ “6.2 Selector lever in N position
s and ignition switched on”, page
ce
54 e
nl
pt
du
an
itte
y li
⇒ “6.3 Selector lever in position Tiptronic ”, page 54
erm
ab
ility
ot p
⇒ “6.4 Ignition and light switched on”, page 55
wit
, is n
h re
⇒ “6.5 Selector lever position indicator”, page 55
hole
spec
It must not be possible to start the engine in the selector lever
es, in part or in w
t to the co
positions “R”, “D” or “S”.
On right-hand drive vehicles, the starter must operate only in se‐
lector lever positions “P” and “N” when the locking button in the
rrectness of i
selector lever handle is not pressed.
l purpos
Over 5 km/h
When the selector lever is shifted to “N”, the selector lever lock
nf
ercia
o
solenoid must not lock the selector lever. Selector lever can be
rm
m
shifted back into a driving range.
atio
om
n in
c
Under 5 km/h
or
thi
te
sd
a
When the selector lever is shifted to “N”, the selector lever lock
iv
o
r
rp
cu
solenoid must lock the selector lever only after approx. 1 second.
o
m
f
Selector lever cannot be shifted out of “N” position until brake

en
ng
t.
yi
pedal is depressed.
Co
Cop py
t. rig
gh ht
6.1 Selector lever in “P” position and ignition pyri by
Vo
o
by c lksw
switched on
cted agen
Prote AG.
• Brake pedal not depressed:

Selector lever is locked and cannot be shifted out of “P” position
with the lock button pressed. Solenoid for selector lever lock
blocks selector lever.
• Brake pedal is depressed:
Solenoid for selector lever lock releases selector lever. It is pos‐
sible to shift into a driving gear. Slowly shift selector lever from
“P” through to “S”, checking whether selector lever position in
dash panel insert corresponds to actual selector lever position.
6.2 Selector lever in “N” position and ignition

switched on
• Brake pedal not depressed:
Selector lever is locked and cannot be shifted out of “N” position
with the lock button pressed. Solenoid for selector lever lock
blocks selector lever.
• Brake pedal is depressed:
Solenoid for selector lever lock releases selector lever. It is pos‐
sible to shift into a driving gear.
6.3 Selector lever in position “Tiptronic”

– Shift selector lever into Tiptronic gate.
The illumination of the “D” symbol in the selector mechanism cov‐
er must go out. “+” and “-” symbols must light up.
Symbols in the dash panel insert must change from “P R N D S”
to “7 6 5 4 3 2 1”.

6.4 Ignition and light switched on

The respective symbol in the shift mechanism cover lights up.
6.5 Selector lever position indicator

Simultaneous illumination of all selector lever position display
segments indicates gearbox emergency running lksw
agemode. es n
o ot g
yV ua
edb 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
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.
6. Checking selector mechanism 55

7 Dismantling and assembling gearbox

⇒ “7.1 Assembly overview - gearbox”, page 56
7.1 Assembly overview - gearbox

⇒ “7.1.1 Renewing bleeder”, page 58
⇒ “7.1.2 Renewing sealing cap”, page 58
1 - Retaining ring
❑ Renew
2 - Clutch end cover
❑ A cover which has been
removed must not be in‐
stalled again.
❑ Lubricate external seal
with dual clutch gearbox
oil - G 052 182 A2- be‐
fore installing.
⇒ page 12
3 - Retaining ring
❑ Renew
4 - Shim
❑ Determine thickness
again if a new clutch has
been fitted ⇒ page 11 agen
AG. Volkswagen AG d
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6 - Clutch aut
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❑ Removing and installing s
ce
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⇒ page 11
un
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7 - Seal, right
erm
ab
ility

ot p
wit
⇒ page 116
is n
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8 - Breather pipe
spec

t to the co
⇒ page 40
9 - Breather cap
rrectne
10 - Plug
s
11 - Seal
s o
cial p
❑ Renew
inform
mer
12 - Gear oil cooler

atio
m
❑ Removing and installing gear oil cooler ⇒ page 38

o
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13 - Bolt, 20 Nm + 45°
te
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❑ Renew
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14 - Filter housing, 20 Nm
t.
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15 - Seal ht. rig
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❑ Renew co Vo
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16 - Heat shield
17 - Oil filter
❑ Renewing ⇒ page 101 lkswage es n
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18 - Bolt, 5 Nm + 90° o
ir se
ran
tee
th or
❑ Renew au ac
ss
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19 - Cable support bracket
un
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❑ For selector lever cable to gearbox
itte
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20 - Gearbox selector lever
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21 - Bolt, 10 Nm + 90° is n
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ole,
❑ Renew
spec
22 - Gearbox
t to the co
23 - Seal, left
❑ Removing and installing ⇒ page 114
rrectne
24 - Seal
ss
❑ Renew
o
cial p
f in
25 - Oil drain plug, 20 Nm
form
mer
❑ For mechatronic unit
atio
om
n
c
26 - Oil level pipe, 3 Nm
i
or
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te
sd
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pr
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Caution
um
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Comply
♦ with the torque
t.
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op
setting precisely.
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The
♦ oil level pipe can cop Vo
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break between the
cted agen
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thread and the collar.
Note
♦ The oil level pipe comes in dif‐

ferent lengths and colours.
♦ If the oil level pipe is renewed, it
is essential that the oil level pipe
appropriate for the gearbox is in‐
stalled ⇒ Electronic Parts Cata‐
logue “ETKA” .
♦ Do not install the oil level pipe
from another gearbox! The oil
level pipe determines the oil level
in the gearbox.
♦ Fitting a different oil level pipe
can result in the oil level in the
gearbox being too high or too
low.
❑ Drain and fill oil ⇒ page 105
27 - Seal
❑ Renew
28 - Oil drain plug, 45 Nm
29 - Bolt, 10 Nm
30 - Gearbox input speed sender - G182- and oil temperature sender in multi-plate clutch - G509-
7. Dismantling and assembling gearbox 57

31 - Mechatronic unit for dual clutch gearbox - J743- n AG. Volkswagen AG do

wage es n
❑ Removing and installing ⇒ page 26 yV
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ua
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32 - Bolt, 8 Nm + 45° ir se tee
tho
u or
❑ Renew ss
a ac
ce
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nl
33 - Cover
pt
du
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❑ With seal
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ab
❑ Renew
ility
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34 - Bolt, 10 Nm + 45°
h re
❑ Renew hole
spec
es, in part or in w
35 - Securing clip
t to the co
❑ Renew
36 - Seal
rrectness of i
❑ Renew
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nf
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7.1.1 Renewing bleeder
rm
m
atio
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Removing
o
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or c
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– Pull off cap -arrow- by hand.

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Prote AG.
– Insert screwdriver -1- between collar of gearbox and breather

pipe -2-.
– Pry off breather pipe -2- with screwdriver -1-.
Installing
– Push on breather pipe -2- powerfully by hand.
Breather pipe must be heard and felt to engage.
– Put on cap.
7.1.2 Renewing sealing cap


♦ -1- Internal puller - Kukko 21/2-
♦ -4- Counter support - Kukko 22/1-

♦ Special wrench - T40297-
♦ Knife, commercially available n AG. Volkswagen AG do

lkswage es n
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Removing ir se
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– Raise vehicle. All 4 supports
aut
of lifting platform must be at same or
ac
height. ss
ce
le
un
pt

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itte
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rm
ab
– Remove front left wheel.

pe
ility
ot
– Remove front left wheel housing liner ⇒ General body repairs,

wit
, is n
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exterior; Rep. gr. 66 ; Wheel housing liners; Removing and

hole
installing front wheel housing liner .

spec
es, in part or in w
– Pierce centre of cap with a knife -1- and remove rubber coating
t to the co
around it. Diameter of opening approx. 15 mm.

rrectness of i
l purpos
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mercia
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tion in
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te o
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Prote AG.
7. Dismantling and assembling gearbox 59

– Pull sealing cap out of gearbox housing . Volkusing

swageninternal puller
14 … 19 mm -B-, e.g. -Kukko w gen AG, and counter
a21/2- AG do
support
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-A-, e.g. -Kukko 22/1-d.by V ua
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– Thoroughly clean ut sealing surface on gearbox housing with a
ho or
lint-free cloth. ss a ac
ce
le
un
Installing
pt
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ility
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ole,
spec
t to the co
– Using key - T40297- , drive new sealing cap into gearbox
housing to stop. Take care not to cant sealing cap.
rrectne
– Check gear oil level ⇒ page 103 .
– Install front left wheel housing liner ⇒ General body repairs,
ss
exterior; Rep. gr. 66 ; Wheel housing liner; Removing and
o
cial p
f i
installing front wheel housing liner .
nform
mer
– Install front left wheel ⇒ Running gear, axles, steering; Rep.
atio
m
gr. 44 ; Wheels, tyres; Changing wheels .

o
n
c
i
or
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te
sd
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pr
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fo
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t.
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Cop py
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Vo
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by
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Prote AG.

8 Removing and installing gearbox

⇒ “8.1 Removing gearbox”, page 61
⇒ “8.2 Installing gearbox”, page 82
⇒ “10.3 Detaching bevel box from gearbox - gearbox removed”,
page 97
⇒ “8.3 Specified torques”, page 82
8.1 Removing gearbox
8.1.1 Removing gearbox, Tiguan 2008 ►

Brief description
The gearbox is removed downwards together with the bevel box.
»From above«
The battery, air filter and starter are removed. Wiring harness of
steering rack is disconnected and »moved clear«. This allows it
to be lowered together with subframe and steering rack. The en‐
gine and gearbox must be supported before the left and right
assembly mounting is removed.
»From below«
Remove noise insulation beneath engine and cover in front left
wheel housing.
Remove -subframe- together with -pendulum support-,
-steering rack- and -both suspension links-.
Both drive shafts are pushed out of gearbox and left installed in
wheel bearing housings. They are only swivelled to one side, but AG. Volkswagen AG d
are left on vehicle. lksw
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au ac
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nl
pt
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an
itte
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ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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orm
m
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n in
or c
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Prote AG.
8. Removing and installing gearbox 61

Special tools and workshop

equipment required
AG. Volkswagen AG d
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♦ Support - 10 - 222 A-
h re
hole
spec
♦ Hook - 10 - 222 A /10-

es, in part or in w
t to the co
♦ Adapter - 10 - 222 A /18-

♦ Adapter - 10 - 222 A /22-
rrectness of i
♦ Tensioning strap - T10038-

l purpos
nf
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orm
m
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or c
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Prote AG.

lkswage es n
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ir se tee
tho
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a ac
ss
ce
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nl
pt
du
an
itte
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ab
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
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Vo
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cted agen
Prote AG.
♦ Engine and gearbox jack - V.A.G 1383 A-

♦ Gearbox support - 3282-
♦ Adapter - 10 - 222 A /28- or adapter - 10 - 222 A /19-
♦ Wedge - T10161-
♦ Engine support, basic set - T40091-
♦ Insert tool, 18 mm - T10179-

AG. Volkswagen AG d
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d
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ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
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do
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t.
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♦ Adapter - 10 - 222 A /16-
Co
Cop py
t. rig
gh
♦ Hose clamps up to 40 mm - 3093- if available, or hose clamps
ht
pyri by
Vo
o
up to 25 mm - 3094-
c by lksw
cted agen
Prote AG.
♦ Socket insert - T10035-
♦ Socket insert - T10061-
♦ Counter-hold tool - T10172-
♦ Drip tray for workshop hoist - VAS 6208-

AG. Volkswagen AG d
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nl
pt
du
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itte
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ab
♦ Shackle - 10 - 222 A /12- ility
ot p
♦ Shock absorber tool set - T10001-

wit
, is n
h re
hole
Removing
spec
es, in part or in w
– Raise vehicle. All 4 supports of lifting platform must be at same

t to the co
height.
– Turn steering to straight-ahead position.
rrectness of i

l purpos
– Remove both front wheels.

nform
ercia

m
at
om

on
c
in t
or

his
ate

do
priv
cum
for
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.

en
ng
t.
yi
27 ; Battery; Removing and installing battery .
Co
Cop py
t. rig
gh
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Removing
ht
pyri by
Vo
o
and installing starter
c by lksw
cted agen
Prote AG.

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


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

or hose clamps to 25 mm - 3094- and remove.
– Remove air intake pipe. ⇒ Rep. gr. 21 ; Turbocharging/su‐
percharging
AG. Volkswagen AG d
agen oes
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or eo
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aut ra
ss c
ce
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un
pt
– Remove upper engine/gearbox connecting bolts.

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
– Upper engine/gearbox connecting bolts can also be removed

using a suitable socket from shock absorber set - T10001- .
m
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
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by c lksw
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Prote AG.

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

used instead of an 18 mm socket.
Rep. gr. 50 ; Noise insulation .
Remove subframe with steering rack. ⇒ Rep. gr. 40 ; Removing

and installing subframe with steering rack
olkswagen AG
en AG. V
– Remove drive shaft kswheat shield, if present, efrom
ag do s
not bevel box ⇒
Vol
Running gear, ed b axles, steering; Rep. gr. 40 ; Repairing
y gu
ara drive
shafts . horis nte
e
t or
au a
– Pressss both drive shafts off gearbox and remove. ⇒ Rep.c gr.
40 ; Removing and installing drive shaft
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
Secure both drive shafts to suspension struts using tensioning

rrectness of i
straps - T10038- .
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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f
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t.
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Cop py
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pyri by
Vo
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by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
h
Sharan
aut 2016 ➤ , Tiguan 2008 ➤ ra
c
s
7-speed
s dual clutch gearbox 0BH - Edition 05.2017
ce
le
un
pt
an
d
itte
Gearbox carrier for 2.0 l - 100/103/130 kW diesel engine
y li
rm
ab
pe
– Unscrew bolts -B- from gearbox carrier on bevel box. Only
ility
ot
loosen bolts -A-, do not remove them.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Gearbox carrier for 2.0 l - 135 kW diesel engine

m
a
com
tio
– Unscrew bolts -A and B-, and remove gearbox carrier for bevel
n in
r
box.
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
Gearbox carrier for petrol engine:

– Unscrew bolts -1- and -3- from gearbox carrier on bevel box.
Only loosen bolts -2-, do not remove them.
– Mark position of propshaft with flexible coupling relative to

output shaft of bevel box -arrows-.

– Unbolt propshaft from bevel box -arrows-.
AG. Volkswagen AG d
agen oes
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byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
– If necessary, counterhold at rear final drive when loosening or
wit
, is n
tightening propshaft.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
– Secure support - T10323- with a bolt on inside rear threaded
c
in t
or
hole for subframe.
his
ate
do
riv
– A securing bolt from the subframe is suitable for this.

p
cum
for
en
g
– Place cloth -A- on support and lay propshaft on that.

n
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
♦ When removing and installing, do not damage seal in the

propshaft flange -arrow-.
♦ Renew propshaft if damaged. ⇒ Propshaft and rear final
drives; Rep. gr. 39 ; Removing and installing propshaft
♦ All parts of propshaft which have been marked relative to each
other must be reinstalled in the same positions.
– Remove front cable holder from »black« gearbox cover.

– Release mechatronic unit connector by turning in

-direction of arrow- and pull off connector.
– Remove all but one »easily accessible« connecting bolt be‐
tween engine and gearbox.
AG. Volkswagen AG d
agen oes
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yV gu
– Set up support device - 10 - 222 A- . Attach hooks to support
ed b ara
nte
is
eyes on engine and support engine and gearbox. Dothnoto raise.
r eo
au ra
c
Adapter - 10-222A/28- may be used in place of adapter
s - 10-222A/
s
ce
le
19- .
un
pt
an
d
itte
y li
rm
ab
pe
Note
ility
ot
wit
, is n
h re
Support eyes may differ from those shown in illustration. Support
hole
spec
engine and gearbox with the available support eyes.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
ti
– Remove securing bolts -arrows- of assembly mounting for en‐
on in
gine⇒ Rep. gr. 10 ; Removing and installing engine .
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.
– Remove securing bolts -arrows- of assembly mounting for

gearbox.

– Then use spindles of support bracket - 10 - 222 A- to lower

engine/gearbox »only« on gearbox side as far as dimension
-a-.
Dimension -a- = about 110mm
The gearbox is separated from the engine in this position.
– Position engine and gearbox jack - V.A.G 1383 A- with gear‐
box support - 3282- under gearbox.
– Mount safety support -1- and hook -2- on gearbox as shown.
lkswage es n
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byV ua
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ir se tee
o
– Mount safety support -3- and pin -4- onaugearbox as shown.
th or
ac
ss
– Remove »last« connecting bolt between engine and gearbox.
ce
e
nl
pt
du
an
– Push gearbox off engine and lower it carefully, ensuring
itte
y li
erm
»clearance« to other components.
ab
ility
ot p
– Detach bevel box from gearbox ⇒ page 97
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
8.1.2 Removing gearbox, Sharan 2016 ►

Brief description
nform
ercia
The gearbox is removed downwards separately. »From above«

m
at
om
ion
The battery with battery tray, air filter and starter are removed.
c
in t
or
The coolant hoses must be clamped off. Support engine and

his
ate
gearbox before left subframe mounting is unbolted.

do
priv
cum
or
»From below«
f
en
ng
t.
yi Co
op
Remove noise insulation beneath engine and cover in front left C py
t. rig
wheel housing.
gh ht
pyri by
Vo
co lksw
by
Remove -subframe- together with -pendulum support-. cted agen
Prote AG.
Both drive shafts are pushed out of gearbox and left installed in
wheel bearing housings. They are only swivelled to one side, but
are left on vehicle.


equipment required
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
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♦ Support - 10 - 222 A-
wit
is n
h re
♦ Sharan adapter - 10-222 A /8-

ole,
spec
♦ Hook - 10 - 222 A /10-

t to the co
♦ Shackle - 10 - 222 A /12-

♦ Bars - 2024 A / 1- of lifting tackle - 2024 A-
rrectne
♦ Gearbox support - 3282-

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

AG. Volkswagen AG d
agen oes
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y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
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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
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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.
♦ Engine and gearbox jack - VAS 6931-

♦ Adjustment plate - 3282/67-
♦ Hose clamps to 25 mm - 3094-
♦ Tensioning strap - T10038-
♦ Set of plugs for engine - VAS 6122-
♦ 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
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
op
♦ Socket insert - T10061- C py
t. rig
gh ht
yri
♦ Counter-hold tool - T10172A-
p by
o Vo
by c lksw
cted agen
♦ Support bridge - T10323-
Prote AG.
♦ Rectangular tube - T40091 / 1- of basic engine support bracket

set - T40091-
♦ Connector - T40091/3- of basic engine support bracket set -
T40091-
♦ Adapter - T40093/3- of supplementary engine support bracket
set - T40093-
♦ Adapter - T40093/3-5 - of supplementary engine support
bracket set - T40093-
Removing:
height.
– Move selector lever to position »P«.
– Remove engine cover panel ⇒ Rep. gr. 10 ; Engine cover
panel; Removing and installing engine cover panel .

– Then pull off grommet -arrow- so that it is not damaged when

supporting engine.
– Remove air filter housing ⇒ Rep. gr. 23 ; Air filter; Removing
and installing air filter housing
– Remove battery with battery tray ⇒ Electrical system; Rep.
gr. 27 ; Battery; Removing and installing battery tray .
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
Removing and installing starter .
– Pry selector lever cable off selector shaft lever -arrow- using
an open-ended spanner.
Caution

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– Carefully push locking mechanisms of selectorkleverwage cable to‐
n AG does
gether -arrows- and remove selector leverbcable
Vol s upwards out not
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– Do not bend or kink cable. ss au ra
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– Clamp off coolant hoses using hose clamps to 25 mm Ø -
an
itte
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3094- and remove.
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ility
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– Seal connecting necks of gear oil cooler using suitable plugs
wit
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from engine bung set - VAS 6122- .
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Disconnect connector -1- for mechatronic unit for dual clutch

gearbox - J743- . To do this, turn rotary locking mechanism
m
at
om
anti-clockwise -arrow-.
ion
c
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or
– Remove charge air line. ⇒ Rep. gr. 21 ; Charge air system;

his
ate
Assembly overview - charge air system

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AG. Volkswagen AG d
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A bolt is located in the starter motor hole -arrow-. This bolt can be
rrectne
removed using socket - T10061- .
ss o
cial p
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• Please note the assembly of the following special tools at this
p by
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point: Prote
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• Adapters - 10-222 A /8- must be mounted with support bracket

put on, as shown.
• Rubber blocks -A- must face outwards.
• -Arrow- = vehicle driving direction.

• Bolt adapter - T40093/3-5 - onto adapter - T40093/3- .

• Connect 2 bars - 2024 A / 1- of support bracket - 2024 A- to‐
gether using shackle - 10 - 222 A /12- .
• 2 holes -arrows- each point in one direction.
Adapter - T40093/3-5 - or adapter - 10-222 A /8- for the support

bracket - 10-222 A- are positioned near radiator grille and plenum
chamber cover.
Therefore, remove following components:
♦ Radiator grille ⇒ Rep. gr. 66 ; Radiator grille
♦ Windscreen wiper arms ⇒ Electrical system; Rep. gr. 92 ;
Windscreen wash/wipe system
♦ Plenum chamber cover ⇒ Rep. gr. 50 ; Plenum chamber
cover G. Volkswagen nA AG do
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– Set up support bracket - 10-222 A- behind
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♦ Spindle - 10 - 222 A /10-
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♦ Connector - T40091/3-
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spec
– Then fit support bracket - 10-222A- behind bonnet support.
es, in part or in w
Position the right adapter - 10-222A/8- next to the bolts as well

t to the co
-arrow-.
– Bolt support bracket - 10-222A- onto left adapter - 10-222A/
rrectness of i
8- .
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– 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 .
Rep. gr. 66 ; Noise insulation; Removing and installing noise
insulation .
– 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 .
– Remove electrical wiring and retainers from sump at front

-arrows-.
– Raise wiring in area of sump and secure it.
AG. Volkswagen AG d
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– Disconnect connector -1- from oil level and oil temperature

ility
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sender - G266- .
wit
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Remove subframe. ⇒ Rep. gr. 40 ; Subframe; Assembly over‐

ole,
spec
view - subframe
t to the co
rrectness o
cial p
f inform
mer
atio
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n
c
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– Remove drive shaft heat shield -1-, if present,
ss au
from bevel box ra
c
(-arrows-) ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive
ce
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nl
shaft .
pt
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– Disconnect both drive shafts from gearbox ⇒ Running gear,
erm
ab
axles, steering; Rep. gr. 40 ; Drive shaft: Removing and in‐
ility
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stalling drive shafts .
wit
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Secure both drive shafts to suspension struts using tensioning

straps - T10038- .
nf
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The surface protection of the shafts must not be damaged.
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– Unscrew bolts -A and B-, and remove gearbox carrier for bevel
box.


Volkswagen AG
– Unbolt propshaft from bevel box -arrows- ⇒ Rep. gr. 39 ;swagen AG. does
Propshaft; Removing and installing propshaft . by
Vol
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– Secure support - T10323- with a bolt on inside rear threaded yri
gh by
ht
hole for subframe.
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– A securing bolt from the subframe is suitable for this.
AG.
– Place cloth -A- on support and lay propshaft on that.
Note
♦ When removing and installing, do not damage seal in the

propshaft flange -arrow-.
♦ Renew propshaft if damaged. ⇒ Rep. gr. 39 ; Propshaft; Re‐
moving and installing propshaft
♦ All parts of propshaft which have been marked relative to each
other must be reinstalled in the same positions.
– Remove all but one »easily accessible« connecting bolt be‐

tween engine and gearbox.

– Remove securing bolts -arrows- of assembly mounting for en‐

gine ⇒ Rep. gr. 10 ; Assembly mountings; Assembly overview
- assembly mountings .
– Remove securing bolts -arrows- of assembly mounting for

gearbox.
AG. Volkswagen AG d
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– Then use spindles of support bracket - 10 - 222 A- to lower
ce
le
un
pt
engine/gearbox »only« on gearbox side as far as dimension

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Dimension -a- = about 110mm

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The gearbox is separated from the engine in this position.

h re
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spec
– Position engine and gearbox jack - V.A.G 1383 A- with gear‐

box support - 3282- under gearbox.

t to the co
rrectness o
– Mount safety support -1- and hook -2- on gearbox as shown.

cial p
f inform
mer
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n
c
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Prote AG.

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

– Remove »last« connecting bolt between engine and gearbox.
– Push gearbox off engine and lower it carefully, ensuring
»clearance« to other components.
Transporting gearbox and attaching to engine and gearbox sup‐
port ⇒ page 86 .
Install gearbox ⇒ page 82 .
8.2 Installing gearbox

Install in the reverse order of removal, observing the following.
– Renew needle bearing -arrow- in crankshaft ⇒ Rep. gr. 13 ;
Crankshaft; Renewing needle bearing in crankshaft .
– Lightly grease journal and splines on gearbox using high-tem‐
perature grease - G052133A2- .
– Check for proper seating of both dowel sleeves between en‐
gine and gearbox.
olksw
– Remove retaining ring and O-ring
swa
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V
shafts.
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– Set gearbox in place,
se
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by adjusting gearbox support.uaran
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It must be possibleauto ac
hand until the flanges
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If this is not so, then »something is wrong«!

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erm
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– Readjust gearbox support until engine and gearbox are

ility
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»aligned with each other«.

wit
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– Install engine/gearbox connecting bolts.

h re
hole
spec

es, in part or in w
t to the co
– Adjust selector lever cable ⇒ page 52 .

– Check coolant level and top up if necessary ⇒ Rep. gr. 19 .
rrectness of i
Specified torques: ⇒ page 82

l purpos
8.3 Specified torques

nform
ercia
⇒ “8.3.1 Gearbox carrier to engine and bevel box”, page 83

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ate
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1 - Direction of travel
- M12 bolts
❑ 80 Nm
❑ 65 Nm, if 18 mm insert -
T10179- is used.
- M10 bolts
❑ 40 Nm
- 2 dowel sleeves in engine
-arrows-
AG. Volkswagen AG d
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ion
c
Component Nm
in t
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ate
Assembly mounting to gearbox (use new bolts) 60 Nm + turn 90° further

do
priv
cum
or
Assembly mounting to engine (use new bolts) ⇒ Rep. gr. 10 ; Removing and installing engine
f
en
ng
t.
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Earth strap to assembly mounting 25
Co
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Heat shield for right drive shaft to bevel box 20
gh ht
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Propshaft to bevel box
by
Prote
cted ⇒ Propshaft and rear final drive; Rep. gr. 39
AG.
agen
Suspension link, coupling rod, pendulum support, ⇒ Running gear, axles, steering; Rep. gr. 40 .
drive shaft
Wheel bolts ⇒ Running gear, axles, steering; Rep. gr. 44 ; Torque
settings for wheel bolts
Bevel box to gearbox 40 Nm + 90° further

♦ Renew bolts.
8.3.1 Gearbox carrier to engine and bevel box

Installation location and tightening sequence:

2.0 l - 100/103/130 kW diesel engine
lkswage es n
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2.0 l - 110/135 kW diesel engine ss
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Item Bolt
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A M10 x 21
erm
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B M10 x 45
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Sequence Bolts Specified torque
spec
1. -A- and -B- Screw in to contact by hand
t to the co
2. Tighten -A- 40 Nm
3. Tighten -B- 40 Nm
rrectne
Petrol engine
ss o
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Installation location and tightening sequence:
f inform
mer
Item Bolt
atio
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1 M10 x 45
n
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2 M10 x 21
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Sequence Bolts Specified torque
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1. -1- and -3- Screw in to contact by hand
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2. Tighten -2- 40 Nm Prote
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agen
3. Tighten -1- and -3- 40 Nm

Heat shield for drive shaft 20 Nm
Heat shield for propshaft
Version 1:
♦ Bolts -arrows- 9 Nm

Version 2:
♦ Bolt -A-: 20 Nm
♦ Bolt -B-: 40 Nm
AG. Volkswagen AG d
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t to the co
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mer
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c
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Cop py
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rig ht
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co Vo
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cted agen
Prote AG.

9 Transporting gearbox and securing

to assembly stand
Always secure heavy parts when transporting them.
Also remember there is oil in the gearbox. Do not turn gearbox
with breathers downwards during transport or while on repair
stand. Oil will run out.
Transporting gearbox
Gearbox can be lifted with lifting tackle - 2024 A- . AG. Volkswagen AG d
agen oes
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Example: securing gearbox to assembly stand.
rrectness of i
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mercia
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ion
c
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or
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ate
do
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cum
for
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t.
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10 Bevel box
⇒ “10.1 Removing and installing bevel box, vehicles with 2.0 l -
100/103/130 kW diesel engine”, page 87
⇒ “10.2 Removing and installing bevel box, vehicles
AG. Volkswwith petrol
agen A
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⇒ “10.3 Detaching bevel box
au
thofrom gearbox - gearbox removed”, eo
ra
page 97 ss c
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un
pt
10.1 Removing and installing bevel box, ve‐
an
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hicles with 2.0 l - 100/103/130 kW diesel
erm
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engine
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On vehicles with 2.0 l - 100/103/130 kW diesel engine, the bevel
spec
box cannot be renewed individually. It must be removed together
with dual clutch gearbox and only then detached from gearbox.
t to the co
⇒ “8 Removing and installing gearbox”, page 61
rrectne
10.2 Removing and installing bevel box, vehicles with petrol engine and vehicles
with 2.0 l - 110/135 kW diesel engine
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
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10. Bevel box 87


equipment required
AG. Volkswagen AG d
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mer
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c
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♦ Multipurpose tool - VW 771-

♦ Hexagon key extension, 8 mm - 3247-
♦ Supplementary set for engine and gearbox support - VW 540/1
B-
♦ Puller - T 10472-
♦ Counter-hold tool - T10172A-
♦ Engine support - T50015A-
♦ Bracket - T10346/1-
Removing
height.
AG. Volkswagen AG d
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After loosening centre bolt, do not lower
ss a vehicle to ground again. ra
c
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un
pt
– Depress brake pedal and loosen bolt of right drive shaft
an
d
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-arrow- (2nd mechanic needed)⇒ Running gear, axles, steer‐
erm
ab
ing; Rep. gr. 40 ; Repairing drive shafts; Removing and
ility
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installing drive shafts .
wit
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ole,
spec
Note
t to the co
So that the propshaft can be turned later in order to loosen it:
rrectne
– Move selector lever to »N« position.
– Remove noise insulation below engine and gearbox. ⇒ Gen‐
ss
eral body repairs, exterior; Rep. gr. 50 ; Noise insulation .
o
cial p
f inform
Vehicles with diesel engine:
mer
atio
om
– Disconnect connector -1-. n

c
i
or
n thi
e
– Unscrew bolt -2- and push auxiliary pump for heating - V488-
t
sd
va
to right side. Do not disconnect any lines ⇒ Rep. gr. 19 ;

i
o
pr
cum
r
fo
Coolant pump, regulation of cooling system; Assembly over‐

en
ng
t.
view - electric coolant pump . Cop
yi Co
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ht. rig
Continued for all vehicles: rig ht
py by
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by lksw
cted agen
Prote AG.
10. Bevel box 89

– Disconnect connector -1- from oil level and oil temperature

sender - G266- .
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Repairing drive shafts; Removing and installing
drive shafts .
– Remove drive shaft heat shield, if present, from bevel box ⇒

Running gear, axles, steering; Rep. gr. 40 ;.Repairing
Volkswagen Adrive
shafts; Removing and installing drivew gen AG .
ashafts G do
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Caution tho eo
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Risk of damage to decoupling element.
ce
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an
d
itte
♦ Observe ⇒ Rep. gr. 26 ; Emission control; Assembly
y li
rm
ab
overview - emission control .
pe
ility
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– Remove front exhaust system from engine, raise it and tie it in
hole
spec
place ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Assembly
es, in part or in w
overview - silencer .
t to the co
If fitted, remove heat shield for propshaft.
Version 1: rrectness of i
l purpos
– Unscrew bolts -arrows- and remove heat shield -A-.

Version 2:
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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rp
cum
fo
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t.
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cted
– Unscrew bolts -A- and -B- from bevel box, and remove heat
agen
Prote AG.
shield -1-.


– Unbolt front propshaft from bevel box -arrows-.

Note
To loosen »next« bolt, turn propshaft further by turning rear

wheels at same time.
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– Unscrew pendulum support bolts -1- from gearbox.

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erm
ab
– Place a cloth on subframe to avoid damaging paint of prop‐

ility
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shaft when it is placed on subframe.

wit
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es, in part or in w
t to the co
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91
Prote AG.
10. Bevel box
– Push font propshaft back to stop. Make sure not to damage

seal -arrow- in centring bush.
– Guide propshaft upwards into tunnel, and use a suitable piece

of wood to support it on subframe.
– Secure bracket - T10346/1- to subframe as shown in illustra‐ agen

AG. Volkswagen AG d
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tion using an M 8 x 25 bolt. yV
olksw not
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– Bolt engine support - T50015- to bracket - T10346/1- and htooris nte
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gearbox at front threaded connection for pendulum support.
s aut ra
c
s
– Force engine/gearbox as far forwards as possible by turning
ce
le
un
pt
spindle of engine support - T50015- . Avoid collisions between
an
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components and radiator cowl.
rm
ab
pe
ility
– Unbolt gearbox carrier.
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Petrol engine:
hole
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es, in part or in w
t to the co
– Unscrew bolts -1-, -2- and -3-, and remove bevel box carrier.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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Sharan 2016
en AG. V
olkswa➤ , ATiguan
gen G do
2008 ➤
waggearbox
7-speed dual Vclutch 0BH - Editiones n05.2017
olks ot gu
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Diesel engine: tho
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s au ra
c
– Unscrew bolts -A and B-, and remove gearbox carrier
s -1- for
ce
le
bevel box.
un
pt
an
d
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pe
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove upper securing bolts -arrows- securing bevel box to
l purpos
gearbox.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
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t.
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Cop py
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– Loosen lower securing bolts securing bevel box to gearbox
AG.
and unscrew only as far as dimension -a-.

Dimension -a- = 15 mm
This prevents the bevel box from falling down immediately when
loosened using multi-purpose tool - VW 771- .
– Fit puller - T 10472- to bevel box.
10. Bevel box 93

– Prepare multi-purpose tool - VW 771- with a washer -a- and 2

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

loosen bevel box from gearbox.
– Remove multi-purpose tool - VW 771- and puller - T10472-
from bevel box.
AG. Volkswagen AG d
agen oes
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nl
– Unscrew lower securing bolts -arrows- and remove bevel box.
pt
du
an
itte
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Installing
erm
ab
ility
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When installing, note the following:
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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orm
m
atio
om
n in
or c
thi
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sd
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m
f
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t.
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t. rig
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pyri by
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Prote AG.

– Grease splines of differential with grease for clutch plate

splines - G 000 100- .
– Install new retaining ring -arrow A- and new O-ring -arrow B-
on right stub shaft.
– Insert bevel box and press against gearbox as far as it will go.
Note
Turn stub shaft if spline position is unfavourable (bevel box cannot

be pressed to stop against gearbox).
– If splines are correctly positioned and shafts are centred, then

bevel box will slide to stop against gearbox.
Caution
To ensure that the retaining ring of the stub shaft engages

properly in the differential bevel gear, strike the face of the
spline stub with a plastic hammer. Do not pull bevel box force‐
fully against gearbox by turning securing bolts. Damage to
gearbox or bevel box could result.
. Volkswagen AG
– Screw on bevel box with new bolts -arrows- until finger-tight,kswagen AG does
not
then tighten. Specified torque: ⇒ page 82 . by
Vol gu
ara
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– Install gearbox carrier. Observe installation locationthoand
r
tight‐ eo
u
ening sequence of bolts ⇒ page 82 . ss a ra
c
ce
le
un
pt
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erm
ab
ility
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wit
is n
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
– If previously removed, attach drive shaft heat shield to bevel

om
box ⇒ Running gear, axles, steering; Rep. gr. 40 ; Repairing

n
c
i
or
drive shafts; Removing and installing drive shafts .

thi
te
sd
iva
– Fit propshaft on bevel box.

pr
cum
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t.
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10. Bevel box 95

AG. Volkswagen AG d
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When removing and installing thethobevel box, do not damage the
r nte
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seal in the propshaft flange -arrow-.
s au Renew propshaft if damaged. ra
c
s
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Join bevel box and propshaft by turning spindle of engine sup‐
port - T50015- .
rrectness of i
– Remove engine support - T50015- together with bracket -
T10346/1- .
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi
– Bolt propshaft onto bevel box -arrows- ⇒ Rep. gr. 39 ; Re‐
Co
op py
moving and installing propshaft .
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– If present, install heat shield for propshaft.
c by lksw
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Prote AG.
Version 1:

Version 2:
– Bolt on pendulum support using »new« bolts. Specified tor‐
ques ⇒ Running gear, axles, steering; Rep. gr. 40 .
– Grease splines of stub shaft with grease - G 000 100- .
– Install right drive shaft ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Repairing drive shafts; Removing and installing drive
shaft .
– Install parts of exhaust system ⇒ Rep. gr. 26 ; Exhaust sys‐
tem .
– Check gear oil in bevel box ⇒ page 132 .
– Following installation, check oil level in gearbox
⇒ page 103 .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 50 ; Noise insulation .
Specified torques: ⇒ page 83
AG. Volkswagen AG d
agen oes
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10.3 Detaching bevel box from gearbox -
Vo gu
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gearbox removed
or eo
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aut ra
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ce
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un
pt
an
d

itte
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rm
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pe
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
ercia
♦ Hexagon key extension, 8 mm - 3247-

m
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com
tion in
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te o
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10. Bevel box 97

AG. Volkswagen AG d
agen oes
♦ Puller - T 10472- olksw not
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or eo
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aut ra
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nl
pt
du
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itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Removing
rrectness of i
– Remove gearbox with bevel box ⇒ page 61 .
l purpos
– Secure gearbox with bevel box to assembly stand

⇒ page 86 .
nform
ercia
In the following illustrations the bevel box is shown in installed

m
at
om
i
condition.
on
c
in t
or
– Remove upper securing bolts -arrows- securing bevel box to
his
ate
gearbox.
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.
– Loosen lower securing bolts securing bevel box to gearbox

and unscrew only as far as dimension -a-.
This prevents the bevel box from falling down immediately when
loosened using multi-purpose tool - VW 771- .
– Fit puller - T 10472- to bevel box.

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

loosen bevel box from gearbox.
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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– Unscrew lower securing bolts -arrows- and remove bevel box.
rm
ab
pe
ility
Installing
ot
wit
, is n
When installing, note the following:
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Grease splines of differential with grease for clutch plate

m
a
com
splines - G 000 100- .
tion in
r
te o
– Install new retaining ring -arrow A- and new O-ring -arrow B-
thi
s
iva
on right stub shaft.
do
r
rp
cum
fo
– Insert bevel box and press against gearbox.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
Note yri
p by
co Vo
by lksw
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Prote
Turn stub shaft if spline position is unfavourable (bevel box cannot
AG.
be pressed to stop against gearbox).
– If splines are correctly positioned and shafts are centred, then

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

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

ferential bevel gear, strike the face of the spline stub several
times with a plastic hammer (weight 1000 - 2000 g).
10. Bevel box 99

– Screw on bevel box with new bolts -arrows- until finger-tight,

then tighten. Specified torque: ⇒ page 82 .
– Installing gearbox ⇒ page 82
– After installing gearbox, check oil level and top up
⇒ page 103 .
AG. Volkswagen AG d
agen oes
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pt
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es, in part or in w
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Prote AG.

11 Oil and oil filter

⇒ “11.1 Renewing oil filter”, page 101
⇒ “11.2 Checking oil level and topping up”, page 103
⇒ “11.3 Draining and filling oil”, page 105
Please also follow instructions:
♦ About this workshop manual ⇒ page 5
♦ Breather pipe of adapter for oil filling - VAS 6262 A- may need
to be shortened.
lkswage es n
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u or
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nl
pt
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an
itte
Shortening breather pipe of adapter for oil filling - VAS 6262 A- :
y li
erm
ab
– In order to ensure that the breather pipe of the adapter for oil
ility
ot p
filling - VAS 6262 A- does not contact the bottom of some oil
wit
, is n
h re
bottles, the pipe must be shortened to the length -a-.
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
The dimension -a- is measured from the shaft (green area in the
l purpos
magnifying glass) of the adapter for oil filling - VAS 6262 A- .
nform
ercia
– Mark dimension -a- on the breather pipe and shorten pipe with
m
at
pipe cutter - VAS 6056/2- .
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
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by
cted agen
Prote AG.
11.1 Renewing oil filter

Oil filter change – »yes or no?«
The oil filter does not have to be changed as a matter of course.
Do not change the filter if:
♦ The gear oil cooler or its O-rings have been renewed and no
coolant has got into the oil.
♦ The oil seal for the selector shaft has been renewed.
♦ The oil seal for the flange shaft was renewed.
♦ Leaking covers in the mechatronic unit, dual clutch or oil pump
have been renewed.
11. Oil and oil filter 101

AG. Volkswagen AG d
agen oes
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Sharan 2016 ➤ , Tiguan aut 2008 ➤
ho eo
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7-speed dual clutch gearbox
ss 0BH - Edition 05.2017 c
ce
e
nl
pt
du
an
The filter must be changed if:
itte
y li
erm
ab
♦ Coolant has got into the oil.
ility
ot p
wit
, is n
♦ Metal particles have been found in the oil.
h re
hole
♦ The clutch is burnt out or has a mechanical defect.
spec
es, in part or in w
t to the co
Note
rrectness of i
Refer to general repair instructions ⇒ page 6 .
l purpos
Removing
nf
ercia
– Move selector lever to position »P«.
orm
m
atio
– Remove air filter housing ⇒ Rep. gr. 24 ; Removing and in‐
om
stalling air filter .
n in
or c
thi
e
Only vehicles with diesel engine

t
sd
iva
o
r
rp
cu
– Remove left coolant pipe together with charge air pipe ⇒ Rep.
o
m
f
en
ng
gr. 19 ; Coolant pipes, coolant temperature sender .

t.
yi Co
Cop py
Continued for all vehicles
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
♦ A residual amount of oil remains in oil filter. It runs out when

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

– Wait about 10 seconds.
This allows the oil to flow from filter housing back into gearbox.
– Now remove filter housing with filter.
– Renew missing or damaged heat shield -2-.
Installing
the following:
– Thoroughly clean oily areas on gearbox.

– Insert new oil filter with collar -arrow- downwards.

– Screw in filter housing and tighten to 20 Nm.
– Check oil level and top up ⇒ page 103 .
11.2 Checking oil level and topping up

If DSG oil must be added, use only oil listed in ⇒ Electronic parts
AG. Volkswagen AG d
catalogue “ETKA” . olkswagen oes
no
V t gu
by
Special tools and workshop equipment rrequired
ise
d ara
nte
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♦ Vehicle diagnosis, testing and information
au system - VAS ra
c
ss
5051B-
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectnes
♦ Used oil collector and extractor - V.A.G 1782-
s 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.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
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Prote AG.
♦ Adapter for oil filling - VAS 6262 A-

Conditions
♦ Vehicle level, all mountings of lifting platform evenly at same
height
♦ Noise insulation removed agen
AG. Volkswagen AG d
oes
ol ksw not
♦ Vehicle diagnosis, testingedand
by V
information system - VAS gu
ara
5051B- is connected. horis nte
eo
ut ra
a
♦ At start of work, oilsstemperature must not be above 45°C. c
ce
e
nl
♦ Test temperature: 35 - 45°C
pt
du
an
itte
y li
Check
erm
ab
ility
ot p
– Connect vehicle diagnosis, testing and information system -
wit
, is n
VAS 5051B- and identify the vehicle in Guided functions .
h re
hole
spec
– Select Dual clutch gearbox .
es, in part or in w
t to the co
– Select Check oil level .
rrectness of i
Note
l purpos
If the oil temperature is above 45°C, allow the gearbox to cool

down.
nform
mercia
at
Engine is running at idling speed with selector lever in “P”.
om
ion
c
in t
– Remove oil drain plug -arrow-.
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.
– Renew oil seal -arrow- of bolt.
Note
Even if oil level is too low, a small amount of oil will initially run out
of oil level pipe because pipe fills up during operation.
– Let surplus oil flow out.

– When excess oil has run out (when it begins only to drip), in‐
stall plug with new seal.
– Top up oil if no oil flows out.
Topping up

– Before screwing adapter for oil filling - VAS 6262 A- onto oil
bottle, measure length of breather pipe, dimension -a- and
shorten ⇒ page 101 .
Note
The dimension -a- is measured from the shaft (green area in the
magnifying glass) of the adapter for oil filling - VAS 6262 A- .
– Screw adapter of adapter for filling oil - VAS 6262 A- hand-

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

AG. Volkswagen AG d
ment at the bottom of the bottle mixes well with the oil.
olks
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– Fill 1.0 litres of oil. au ra
c
ss
ce
e
– Pull off adapter for oil filling - VAS 6262- at plug-in connector
nl
pt
du
and check:
an
itte
y li
erm
ab
If oil now flows out of hole in adapter:
ility
ot p
wit
Oil does not need topping up.
, is n
h re
hole
– Allow surplus oil to drain out.
spec
es, in part or in w
– When excess oil has run out (when it begins only to drip), re‐
t to the co
move adapter for filling oil - VAS 6262 A- and install plug with
new seal.
rrectness of i
If no oil drips out of inspection hole:
l purpos
– If a further litre has to be added ⇒ page 103 .
nf
ercia
WARNING orm
m
atio
m
An oil level which is too low or too high will impair the function
o
n in
c
of the gearbox.
or
thi
te
sd
iva
o
r
rp
cu
o
Torque setting for drain plug: 45 Nm

f
en
ng
t.
yi Co
Cop py
t. rig
11.3 Draining and filling oil
gh ht
pyri by
Vo
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by c lksw
cted
If DSG oil must be added, use only oil listed in ⇒ Electronic parts
agen
Prote AG.
catalogue “ETKA” .
Brief description
First read the oil temperature. If it is above 50°C, allow the gear‐
box to cool down.
With engine stopped, unscrew and remove overflow pipe and let
the oil drain out. Then reinstall overflow pipe and »overfill« gear‐
box with oil.
Then start engine and drain excess oil until oil level attains level
of overflow pipe.


♦ Vehicle diagnosis, testing and information system - VAS
5051B-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
c
♦ Used oil collector and extractor - V.A.G 1782- 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
♦ Adapter for oil filling - VAS 6262 A-
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Conditions
♦ Engine switched off
♦ Vehicle level, all mountings of lifting platform evenly at same
height
♦ Noise insulation removed if previously fitted
♦ Selector lever at “P”
♦ Vehicle diagnosis, testing and information system - VAS
5051B- is connected.
♦ At start of work, oil temperature must not be above 45 °C.
Procedure
– Comply with rules for cleanliness when working on gearbox
⇒ page 5 .
– Only gear oil available as spare part is allowed to be used for
dual clutch gearbox. Other oils will lead to malfunctions or fail‐
ure of the gearbox ⇒ Electronic Parts Catalogue (ETKA) .

WARNING
Danger of injury from hot gear oil! AG. Volkswagen AG d

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

– Remove oil level pipe -arrow- and allow oil to run out.
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
– Remove oil drain plug -arrow- from mechatronic unit.
es, in part or in w
t to the co
Note
rrectness of i
A further approx. 1.2 litres of oil will run out.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
– Renew seal -arrow- and reinstall oil drain plug of mechatronic
fo
en
ng
unit, tightening to 20 Nm.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
Note by c lksw
cted agen
Prote AG.
♦ Normally, there is no need to remove oil filter.

♦ Oil filter change “Yes or no?” ⇒ page 101
– Screw oil level pipe -arrow- 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 101 .
AG. Volkswagen AG d
agen oes
yV
olksw Note not
gu
d b ara
ise nte
r
The dimensionut -a- is measured from the shaft (green area in
ho e o the
ra
magnifying
s glass) of the adapter for oil filling - VAS 6262 A- . c
s a
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
– Screw adapter of adapter for filling oil - VAS 6262 A- hand-
wit
is n
tight into inspection hole.
h re
ole,
spec
WARNING
t to the co
Shake bottles thoroughly before opening to ensure that sedi‐
ment at the bottom of the bottle mixes well with the oil.
rrectnes
During filling, the adapter for oil filling - VAS 6262 A- and bottle
s o
cial p
must always be held higher than the gearbox.
f inform
mer
– Fill 5.5 litres of oil.

atio
m
– When changing bottles, close tap on adapter.

o
n
c
i
or
n thi
– Close tap on adapter when 5.5 litres of oil have been added
te
sd
va
to gearbox.
i
o
pr
cum
r
fo
– Start engine. The adapter for filling oil - VAS 6262 A- may re‐
en
ng
t.
yi
main connected.
Co
Cop py
ht. rig
ht
– Depress brake pedal and select each selector lever position
rig by
opy Vo
for about 3 seconds, then move lever back to »P« by c lksw
cted agen
Prote AG.
– Do NOT switch off engine.
– Then check oil level and top up. ⇒ page 103

AG. Volkswagen AG d
35 – Gears, shafts d by Volksw
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gears and shafts
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110 Rep. gr.35 - Gears, shafts

39 – Final drive - differentialagen AG. Volkswagen AG d

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1 Bevel box d ara
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1.1 Assembly overview - bevel box
pt
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1 - Outer left seal
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❑ Between bevel box and
hole
gearbox
spec
es, in part or in w
❑ To renew, remove bevel
t to the co
box ⇒ page 87
❑ In case of leakage, also
renew »inner« seal
rrectness of i
⇒ Item 2 (page 111)
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❑ Renewing ⇒ page 118

2 - Inner left seal
nform
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❑ Between bevel box and

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tion in
❑ To renew, remove bevel
r
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box ⇒ page 87
s
iva
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❑ In case of leakage, also

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renew »outer« seal
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⇒ Item 1 (page 111)
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3 - Bevel box
by lksw
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Prote AG.
⇒ page 87
4 - Seal
❑ Right (drive shaft side)
❑ Seal can be renewed
with bevel box installed
5 - Cap
❑ Right (drive shaft side),
if there is one
❑ Seal can be renewed
with bevel box installed
6 - Retaining ring
❑ Always renew
❑ Insert in circumferential groove in stub shaft
7 - O-ring
❑ Always renew
❑ Insert in circumferential groove in stub shaft
8 - Stub shaft
❑ To remove and install, remove bevel box ⇒ page 87
9 - Needle bearing (polygon bearing)
1. Bevel box 111

10 - Retaining ring
❑ Always renew
11 - Hexagon nut, 480 Nm
❑ Install using locking fluid - D 000 600-
12 - Output flange
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13 - Seal Vol
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❑ To renew, remove bevel box o⇒ris page 87
e ran
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th or
❑ Renewing ⇒ page 123 s a u ac
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14 - Bolt, 25 Nm
un
pt
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❑ Tighten diagonally and alternately

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15 - Pinion housing
ility
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❑ With shaft bevel gear
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hole
❑ Pinion housing fits only in one position.
spec
es, in part or in w
❑ Installing: place pinion housing loosely on bevel box, screw in all bolts by hand, screw in alternately until
t to the co
heads contact casing and then tighten bolts alternately
16 - O-ring
rrectness of i
❑ To renew, unscrew bolts ⇒ Item 14 (page 112) and carefully lever off pinion housing at projecting webs
on outside edge
l purpos
❑ Do not remove hexagon nut ⇒ Item 11 (page 112) and output flange ⇒ Item 12 (page 112)
nform
mercia
a
com
tion in
r
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s
iva
do
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t.
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Cop py
t. rig
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Prote AG.
112 Rep. gr.39 - Final drive - differential

AG. Volkswagen AG d
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2 Overview of fitting locations - seals yV
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1 - Stub shaft O-ring
ce
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un
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❑ Renew
an
d
itte
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erm
ab
2 - Seal right, bevel box
ility
ot p
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is n
⇒ page 121
h re
ole,
spec
3 - Stub shaft
t to the co
4 - Right oil seal, stub shaft
❑ Item can be disregarded
rrectne
5 - Output shaft seal
ss
⇒ page 123
o
cial p
f in
6 - Deflector ring
form
mer
❑ Item can be disregarded
atio
om
n
c
7 - Left oil seal, stub shaft
i
or
n thi
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t
sd
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⇒ page 119
pr
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8 - Seal left, bevel box

t.
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rig
⇒ page 119 py by
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9 - Seal, right
agen
Prote AG.

⇒ page 116
10 - Seal, left
⇒ page 114
2. Overview of fitting locations - seals 113

3 Renewing seals on gearbox

⇒ “3.1 Renewing oil seal for left flange shaft”, page 114
⇒ “3.2 Renewing right seal (between gearbox and bevel box) on
gearbox”, page 116
3.1 Renewing oil seal for left flange shaft

♦ Puller - T10055-
AG. Volkswagen AG d
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spec
es, in part or in w
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♦ Drip tray for workshop hoist - VAS 6208- thi

s
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rp
cum
fo
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.
♦ Electric drill, commercially available

Removing
– Remove left drive shaft ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Front suspension, drive shaft; Drive shafts .

Note
Only drill through sheet metal ring (about 3 mm), otherwise bear‐
ing located behind it might be damaged.
– Grease drill bit -3- so that metal chips adhere to it.

– Seal drive shaft aperture on transmission with a clean cloth
-2-.
– Carefully drill a hole with a drill bit -3- (diameter 2 to 4 mm) into
outer sheet metal ring -1- of oil seal.
AG. Volkswagen AG d
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– Screw a self-tapping screw, approx. 4 mm in diameter, into
ce
le
un
pt
hole drilled in oil seal. Do not screw in sheet metal screw too
an
d
itte
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far to avoid damaging bearing behind it.
rm
ab
pe
ility
– Place drip tray for workshop hoist - VAS 6208- below gearbox.
ot
wit
, is n
– Pull out oil seal using puller - T10055- and adapter - h re

hole
T10055/2- .
spec
es, in part or in w
t to the co
Make sure no metal chips get into gearbox and into opening for
drive shaft. Vacuum out metal chips first if necessary.
– Carefully remove cloths and make sure that no metal chips get
rrectness of i
into gearbox.
l purpos
– Carefully clean gearbox and opening for drive shaft.

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

m
a
com
Installing
ion in
r
te o

thi
s
iva
the following:
do
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fo
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Before seal is installed, apply sealing grease for radial oil seal -
n
t.
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G 052 128 A1- to sealing lips and cavity, and apply ⇒ DSG oil to
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outer circumference. rig ht
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Installation position:
Prote
cted AG.
agen
Open side of oil seal faces gearbox.
3. Renewing seals on gearbox 115

– Drive oil seal in to stop with thrust piece - T10457- . Do not

cant oil seal in the process.
– Grease splines of stub shaft with universal grease - G 060 735
A2- .
– Install left drive shaft ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Front suspension, drive shaft; Drive shafts .
3.2 Renewing right seal (between gearbox

and bevel box) on gearbox
♦ Extractor hooks -T20143-
♦ Thrust piece - T10458- agen

AG. Volkswagen AG d
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byV gu
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ris nte
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aut ra
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nl
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du
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itte
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ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Removing
rrectness of i
– Remove bevel box ⇒ page 87 .

l purpos
– Lever out seal on gearbox using puller hook - T20143/1- or -

T20143/2- .
nf
ercia
Installing
orm
m
atio

om
n in
the following:
or c
thi
te
sd
iva
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cu
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f
en
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t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Before seal is installed, apply sealing grease for radial oil seal -
G 052 128 A1- to sealing lips and cavity, and apply ⇒ DSG oil to
outer circumference.
Installation position:
Open side of oil seal faces gearbox.
– Drive oil seal in to stop with thrust piece - T10458- . Do not

cant oil seal in the process.
– Install bevel box ⇒ page 87 .
lkswage es n
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un
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d
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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.
3. Renewing seals on gearbox 117

4 Renewing seals on bevel box

AG. Volkswagen AG d
agen oes
Note yV
olksw not
gu
d b ara
ise nte
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Bevel box is usually removed to renew seals ⇒ pageuth111 . In this
o eo
ra
case examine all seals carefully and renew any that
s are defective.
s a c
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nl
pt
du
an
⇒ “4.1 Renewing seals on left (between bevel box and gearbox)”,
itte
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page 119
erm
ab
ility
ot p
⇒ “4.2 Renewing right seal (drive shaft side)”, page 121
wit
, is n
h re
⇒ “4.3 Renewing output flange oil seal (bevel box removed)”,
hole
spec
page 123
es, in part or in w
t to the co
⇒ “4.4 Renewing needle bearing (polygon bearing) for stub shaft”,
page 128
rrectness of i
♦ Multi-purpose tool - VW 771- and multi-purpose tool - VW
l purpos
771/37-
♦ Extractor hook - T20143-
nf
ercia
orm
m
atio
om
n in
c

or
thi
te
sd
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Thrust piece -T10380-

♦ Hub grease cap puller - VW 637/2-
4.1 Renewing seals on left (between bevel

box and gearbox)
lkswage es n
Note byV
o ot g
ua
d ran
ir se tee
o
Seals (Qty. 2)aucan be renewed only with bevel box removed. Al‐
th or
ac
ways renew both seals. ss
ce
le
un
pt
an
d
itte
Removing
y li
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ab
pe

ility
ot
wit
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Remove »outer« seal. h re

hole
spec
– Lever out seal using puller hook - T20143/2- .
es, in part or in w
t to the co
Remove »inner« seal.

rrectness of i
Note
l purpos
So that new seal will not be damaged later on:

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
– Remove retaining ring -1- from stub shaft.

um
fo
en
ng
t.
– Carefully use plastic mallet -2- to drive stub shaft out in direc‐
yi Co
op py
tion of arrow. t. C rig
gh ht
pyri by
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co lksw
by
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Prote AG.
4. Renewing seals on bevel box 119

– Pull out seal for stub shaft on gearbox side.

Installing
Drive in »outer« seal.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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ris nte
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aut ra
ss c
ce
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nl
pt
du
an
itte
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– Half-fill space between sealing lip and dust lip of new seal
ility
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-arrow- with sealing grease - G 052 128 A1- .
wit
, is n
h re
hole
– Lightly oil outer circumference of new oil seal.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
i
– Drive in seal to stop.
on
c
in t
or
Drive in »inner« seal.
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.


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

lksw AG. Vo agen AG
agen do
– Check gear
Vooil
lkswin bevel box ⇒ page 132
es n
.ot g
by ua
ed ran
oris tee
th or
au ac
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e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
4.2 Renewing right seal (drive shaft side)

es, in part or in w
t to the co
Note
rrectness of i
Seal can be renewed with bevel box installed.

l purpos
Removing
nform
ercia
– Raise vehicle.
m
at
om
ion
– Remove noise insulation located beneath engine/gearbox ⇒

c
in t
or
General body repairs, exterior; Rep. gr. 50 ; Noise insulation .

his
ate
do
riv
– Remove right drive shaft. ⇒ Running gear, axles, steering;

p
cum
or
Rep. gr. 40 ; Removing and installing drive shafts .

f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
Note py by
co Vo
by lksw
cted agen
Prote AG.
Some bevel boxes have protective cap -arrow- installed on right.
Renew protective cap each time after removing.
Pull off protective cap.

– Position hub grease cap puller - VW 637/2- in recess -arrow-

and lever off protective cap.
– Remove retaining ring -1- and seal -2- from stub shaft.
– Place drip tray under bevel box.
Lever out seal.

Installing
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
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erm
ab

ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
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f
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t.
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Cop py
t. rig
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pyri by
Vo
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122
c by lksw
cted agen
Rep. gr.39 - Final drive - differential Prote AG.

– Fit new retaining ring and new seal on stub shaft.
Bevel box with protective cap
– Drive on new protective cap to stop.

– Check gear oil in bevel box ⇒ page 132 .
– Install drive shaft ⇒ Running gear, axles, steering; Rep. gr.
40 ; Removing and installing drive shafts .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
4.3 Renewing output flange oil seal (bevel

nl
pt
du
an
itte
box removed)
y li
erm
ab
ility
ot p
wit
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Note h re
hole
spec
es, in part or in w
Seal can be renewed only with bevel box removed.

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.


equipment required
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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au ra
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nl
pt
du
an
itte
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ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
atio
om
n in
or c
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
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Prote AG.
♦ Support clamp - VW 313-

♦ Tube - VW 516-
♦ Thrust plate - 40-105-
♦ Gearbox support - T10108-
♦ Support plate - T10108/1-

AG. Volkswagen AG d
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olksw not
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horis Sharan 2016
nte ➤ , Tiguan 2008 ➤
eo
aut 7-speed dual clutch gearbox 0BHr ac- Edition 05.2017
ss
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nl
pt
du
an
itte
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erm
ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
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.

♦ -1- Two-arm puller - Kukko 20/10-
♦ Three-arm puller - Kukko 45-2-

♦ Extractor hook - VW 771/37-
♦ Sealing grease - G 052 128 A1-

♦ 2 bolts M10 x 30
♦ 4 nuts M12 x 10
Removing
– Set bevel box in gearbox support - T10108- on hole -arrow-
marked with the number -5-.
A - Lay nuts M12 x 10 (qty. 4) between bevel box and gearbox
support . Nuts function as spacers.
– Then align bevel box with hole opposite and secure.
olks
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byV ua
– Place drip tray for workshop hoist - VAS 6208- ris underneath.
ed ran
tee
tho
or
– Drain oil from bevel box. ss
au ac
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
– Lock bevel box output flange with stop plate - T10108/1- ,

l purpos
screwing in M 10 x 30 bolts -arrows-.

– Unscrew hexagon nut for output flange.
nform
ercia
A - 36 mm socket for 3/4" drive

m
a
com
tion in
– Swing bevel box so that output flange points upwards.

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

– Pull output flange off shaft bevel gear of bevel box.

A - Three arm puller , e.g. -Kukko 45-2-
– Pull out seal -A- for output flange.

– Clean residual locking fluid from thread of shaft bevel gear.
Installing
– Drive in new oil seal to stop using thrust piece - T10049- .

– Half-fill space between sealing lip and dust lip with sealing
grease - G 052 128 A1- .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
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un
pt
an
d
itte
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ab
pe
ility
– Pull in output flange using two arm puller -A-.

ot
wit
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A - Two-arm puller , e.g. -Kukko 20/10-

h re
hole
spec
Please note the following:

es, in part or in w
t to the co
• Use new or nearly new puller hooks!

• The output flange must not be canted.
rrectness of i
• Fit puller hooks as far as they will go onto underside of pinion

housing.
l purpos
• Take up slack on puller hooks fully with two arm puller

-arrows-.
nform
mercia
• Puller hooks should not bend outwards.

a
com
tion in
• If necessary, halt pulling process, pull off output flange again

r
te o
thi
and restart pulling process.

s
iva
do
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cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

– Coat thread of new hexagon nut with locking fluid D 000 600.
– Tightening new hexagon nut for output flange to specified tor‐
que.
Specified torque: ⇒ Item 11 (page 112)
A - 36 mm socket for 3/4" drive olkswage es n
ot g
b yV ua
– Install bevel box ⇒ page 87 . ir se
d ran
tee
tho
or
– Check gear oil in bevel box ⇒ page
ss
au
132 . ac
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
4.4 Renewing needle bearing (polygon bearing) for stub shaft
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
equipment required
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.
♦ Pressure plate - VW 401-

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

♦ Tensioning device - T10047-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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aut ra
ss c
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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.

♦ Thrust pieces for drive pinion bearing - VW 470-
♦ Socket insert - T10107 A-
♦ -3- splitter 2275 mm , e.g. -Kukko 17/1-
Removing
– Remove noise insulation below engine and gearbox. ⇒ Gen‐
eral body repairs, exterior; Rep. gr. 66

– Remove retaining ring -1- from stub shaft.

– Carefully use plastic mallet -2- to drive stub shaft out in direc‐
tion of arrow.
– Align both parts of tool so that marks “B” are opposite one
another.
– The shoulders -arrows- must then be below the bearing.
– Now screw both halves together to stop.
– Lever off retaining ring -A- for. Vneedle

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

shaft during pressing procedure -arrow-.
– Secure needle bearing with a new retaining ring.
– Carefully use plastic mallet to drive in stub shaft to stop.
– Fit new retaining ring -1- on stub shaft.

– Install right drive shaft ⇒ Running gear - front and four wheel
drive; Rep. gr. 40 ; Removing and installing drive shafts .
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Rep. gr. 50 ; Noise insulation .
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– Place drip tray for workshop hoist - VAS 6208- underneath.
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Cover area beneath oil filler plug -arrow- with a cloth.

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– Screw in new oil filler plug -arrow-.

– Tighten bolt to specified torque ⇒ page 134 .
5.2 Filling gear oil in bevel box

♦ Filling device - VAS 6291 A-

♦ Adapter - VAS 6291/2-
♦ For some oil bottles adapter - VAS 6262/6- must be used as

well.
♦ Not illustrated: Torque wrench - V.A.G 1331-

Requirement
• Vehicle is level.
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
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– If fitted, remove right drive shaft heat shield from bevelVol box
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-arrows- ⇒ Running gear, axles, steering; Rep.sgr. ed by 40 ; Drive ara
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5. Checking and topping up gear oil in bevel box
– Screw adapter - VAS 6291/2- -A- in to stop.

– Engage elbow -B- in adapter -A-.
– Top up with oil.
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VAS 6291/2- .
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– Screw in »old« oil drain plug and tighten slightly.
– Start engine, engage gear and allow gearbox to turn for ap‐
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gr. 50 ; Noise insulation .
5.3 Specified torque

Oil filler plug 15 Nm
♦ Renew bolt

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Service

7-speed dual clutch gearbox 0BH

Service Department. Technical Information

39 - Final drive - differential

All rights reserved.

Copyright © 2017 Volkswagen AG, Wolfsburg D3E802C2DEC

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

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

2 Removing and installing gear oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3 Emergency release of selector lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Removing and installing handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

4.2 Moving push button in the handle to installation position . . . . . . . . . . . . . . . . . . . . . . . . . . 45

6 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

7 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

5.1 Checking gear oil in bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

5.2 Filling gear oil in bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

5.3 Specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

1.1 General safety provisions

Risk of injury and accident by accidental engagement of gear

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

To prevent damage to the electronic components when dis‐

♦ Observe the necessary measures when disconnecting the

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

1.3 Notes on tow-starting/towing

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

1.4 Safety precautions when using testers

Risk of accident due to distraction and inadequate securing of

2 Rep. gr.00 - Technical data

To prevent damage to the electronic components when dis‐

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

2.1 Identification of gearbox

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

4 Rep. gr.00 - Technical data

3.1 General information

posed hydraulic actuation of the dual clutch, it is operated like

an automatic gearbox. In other words, the gears are engaged

automatically or manually via the Tiptronic system. There is no

sition is not transferred by mechanical means via the selector

cally via the selector lever cable.

Gear change point variations for gradients

An additional gear change map automatically selects gear

changes for gradients dependent upon accelerator pedal position

and driving speed.

• Gear change map for extreme uphill stretches is matched to

• If a gear is selected directly via the Tiptronic system, it is also

3.2 Rules for cleanliness

♦ If repair work cannot be performed immediately, cover opened

3.3 General repair instructions

For a complete list of special tools used in this workshop manual,

see ⇒ "Workshop equipment and special tools" .

do not run engine or tow vehicle.

areas and then loosen bolts.

♦ When installing the gearbox, ensure that dowel sleeves be‐

tween the engine and gearbox are correctly located.

6 Rep. gr.00 - Technical data

Oil drain and inspection plug

3.4 Gaskets and seals

gearbox and top up if necessary ⇒ page 103 .

3.5 Nuts and bolts

and housings diagonally.