Manual Transmision 0GC PDF

Service
Workshop Manual
Golf 2017 ➤ , Golf Sportsvan 2015 ➤ ,
Golf Sportsvan 2018 ➤ ,
Golf Variant 2017 ➤ , Tiguan 2016 ➤
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00 - Technical data
30 - Clutch
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34 - Controls, housing
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35 - Gears, shafts
39 - Final drive - differential
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2018 Volkswagen AG, Wolfsburg D4B806A4276

Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ➤ , Golf Varia ...
7-speed dual clutch gearbox 0GC - Edition 07.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 General safety provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 2
1.3 Notes on tow-starting/towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Safety precautions when using testers and measuring instruments during a road test . . . . 2
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 General information . . . . . . . . . . . . . . . . . . . . . .w.ag.e.n.A.G.. V. o.lk.s.w.ag. e.n.A.G.d.oe. . . . . . . . . . . . . . . 5
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3.2 Rules for cleanliness . . . . . . . . . . . . . . . . b. y.V.o.l . . . . . . . . . . . . . . . . . . . . .n.ot.g.ua. . . . . . . . . . 5
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3.3 General repair instructions . . . . . . . . .or.is.e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a.n.te.e . . . . . . 5
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3.4 Gaskets and seals . . . . . . . . . . . . s.au. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .r a.c. . . . 6
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3.5 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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4.1 Allocation gearbox - engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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4.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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5 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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5.1 Overview of fitting locations - electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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1.1 Assembly overview - dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 Removing and installing clutch end cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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1.3 Removing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.4 Installing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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1 Mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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1.1 Assembly overview - mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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1.2 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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1.3 Removing and installing mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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2 Bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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2.1 Assembly overview - bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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2.2 Distinguishing between different types of bevel boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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2.3 Removing bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.4 Installing bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.1 Assembly overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.2 Emergency release from position P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.3 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.4 Moving push-button in the handle to installation position . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.5 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.6 Removing and installing gear selector cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.7 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.8 Checking and adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.9 Renewing selector shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.1 Specified torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.2 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.3 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
5 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Contents i
5.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

6 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
6.1 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
6.2 Transporting front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
7 Securing to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7.1 Installing gearbox to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7.2 Securing front differential lock to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . 158
8 Gear oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
8.1 Assembly overview - gear oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
8.2 Removing and installing gear oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
8.3 Removing and installing gear oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
8.4 Removing and installing motor for auxiliary hydraulic pump 1 for gearbox oil V475 . . . . . . 164
9 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . .. V. o.lk.s.w.ag. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
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9.3 Checking gear oil leveluthor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . te.e.o . . . . . . . . . . . . . . . . . 168
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oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ac. . . . . . . . . . . . . . . . 171
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10 Front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

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10.1 Assembly overview - front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
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10.2 Removing front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
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10.3 Installing front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
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10.4 Removing and installing differential lock control unit J647 . . . . . . . . . . . . . . . . . . . . . . . . 180
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35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
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1 Currently, no repairs can be made to gears and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
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1 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
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1.1 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
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1.2 Draining and filling gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
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2 Oil for front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

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2.1 Checking oil level for front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

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2.2 Draining and filling oil for front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
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3 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

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3.1 Overview of fitting locations - seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

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3.2 Renewing left seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
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3.3 Renewing right oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
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4 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
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4.1 Removing and installing right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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5 Components of front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

5.1 Assembly overview - components of front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . 202
5.2 Checking function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
5.3 Removing and installing pump for front differential lock V181 . . . . . . . . . . . . . . . . . . . . . . 203
5.4 Removing and installing coupling for front differential lock . . . . . . . . . . . . . . . . . . . . . . . . 205
5.5 Renewing seals for front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
5.6 Renewing ball bearing for flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
6 Components of bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
6.1 Assembly overview - components of bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
6.2 Renewing bevel box seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
6.3 Renewing output flange and redetermining thickness of shim . . . . . . . . . . . . . . . . . . . . . . 241
ii Contents
00 – Technical data
1 Safety information
(VRL011928; Edition 07.2018)
⇒ “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
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Risk of injury and accident by accidental engagement of gear
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♦ Before working on vehicle with engine running, move se‐
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To prevent personal injury and damage to or destruction of elec‐
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♦ Connect and disconnect measuring and testing devices only
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– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and reconnecting battery .
1. Safety information 1
1.2 Safety measures when working on ve‐

hicles with a start/stop system
Observe the following when working on vehicles with a start/stop
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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

the “N” position, and the vehicle must be towed at a speed
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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 the
event of an accident.
• Operating test instruments and measuring equipment
while driving can cause 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:
♦ Take 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 .
AG. Volkswagen AG d
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1. Safety information 3
2 Identification
2.1 Gearbox identification

gen A n AG G. Volkswage
The gearbox code can be found on top Vof swa gearbox, near the does no
olkthe t gu
starter. ed
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The gearbox codes can be found on top of the gearbox.

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

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

Gear oil
The “0GC” dual clutch gearbox only has one oil system.
The oil system lubricates the gears, shafts, final drives, clutches
and mechatronic unit for dual clutch gearbox - J743- .
Only use gear oil in accordance with ⇒ Electronic parts cata‐
logue .
Gear oil filter change - »Yes or no?«
• The gear oil filter does not have to be changed as a matter of
course.
Do not change the filter if:
♦ The gear oil cooler or its O-rings were renewed and no coolant
has got into the oil.
♦ Seals and O-rings of the gearbox were renewed.
♦ The sump or mechatronic unit were renewed.
en AG. V
olkswagen AG
ag does
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♦ The service interval was reached.by Vol gu
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Filter must be changed if: tho eo
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♦ Metal particles have beens found in the oil.
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♦ The clutch is burnt or has a mechanical defect.

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3.2 Rules for cleanliness

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♦ First thoroughly clean connecting points and surrounding

h re
areas and then loosen bolts.

hole
spec
es, in part or in w
♦ Seal open lines and connections immediately using clean

t to the co
plugs or sealing caps from engine bung set - VAS 6122- .

♦ Place removed parts on a clean surface and cover them to
rrectness of i
prevent them from getting dirty. Use sheeting and paper for
this purpose. Use lint-free cloths only.
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♦ Make sure that no dirt can enter an »open« gearbox.

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

packaging until immediately before installing.
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♦ If repair work cannot be performed immediately, cover opened

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parts carefully.
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♦ Protect disconnected electrical connectors from dirt and water,

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and reconnect them only when dry.

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3.3 General repair instructions Cop py
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To ensure flawless and successful gearbox repairs, the greatest
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care and cleanliness as well as the use of good and proper tools
agen
Prote AG.
are essential. Also note the basic rules on safety when performing
repair procedures.
3. Repair instructions 5
A number of general notes on the individual repair procedures,

which were otherwise repeated in the relevant sections of the
manual, are summarised here. They apply for this particular work‐
shop manual.
Guided Fault Finding, vehicle self-diagnosis and test instruments
. Volkswagen AG
gen AG does
♦ Before performing repairs to the gearbox, determine the causeVolkswa not
of the fault as accurately as possible ⇒ Vehicle diagnostic db
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tester, Guided Fault Finding , Vehicle Self-Diagnosis rise nte
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or Test Instruments . ut ra
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Special tool
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For a complete list of special tools used in this workshop manual,
erm
ab
see ⇒ "Workshop equipment and special tools" .
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Gearbox
, is n
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hole
Always make sure that no dirt can enter an »open« gearbox. In
spec
particular, dirt entering an »exposed« mechatronic unit for dual
es, in part or in w
t to the co
clutch gearbox - J743- and/or oil pump can lead to gearbox failure.
♦ If gearbox covers have been unbolted or gearbox has no fluid,
do not run engine or tow vehicle.
rrectness of i
♦ First thoroughly clean connecting points and surrounding
l purpos
areas and then loosen bolts.

♦ When installing the gearbox, ensure that dowel sleeves be‐
nform
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tween the engine and gearbox are correctly located.

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Locking devices
on
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or
♦ Do not overstretch retaining rings.
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ate
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♦ Always renew retaining rings which have been damaged or

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or
overstretched.
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♦ Retaining rings must locate properly in grooves.
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3.4 Gaskets and seals
cop Vo
by lksw
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Prote AG.
♦ 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 lubricants will cause
problems in function.
♦ Coat O-rings with dual clutch gearbox oil to prevent pinching
of rings during assembly.
♦ After renewing gaskets, O-rings and seals, check oil level in
gearbox and top up if necessary ⇒ page 166 .

AG. Volkswagen AG d
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Golf 2017 ➤ , Golf Sportsvanorise 2015 ➤ , Golf Sportsvan 2018 ➤ , Golf nteVaria ...
eo
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a 7-speed dual clutch gearbox 0GC - Edition 07.2018
ut ra
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3.5 Nuts and bolts
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♦ Loosen and tighten securing bolts and securing nut for covers
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and housings diagonally.
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♦ Specified torques given are for unlubricated nuts, bolts and
hole
screws.
spec
es, in part or in w
t to the co
♦ Clean threads of bolts which are to be installed with locking
fluid using a wire brush. Then insert bolts with locking fluid -
AMV 185 101 A1- .
rrectness of i
♦ Use a thread chaser to clear residual locking fluid from all
threaded holes into which self-locking bolts are to be screwed.
Otherwise there is a danger of bolts shearing when subse‐ l purpos
quently being removed.
nform
ercia
♦ Check pitch of thread, to ensure correct thread chaser is used

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at
to clean threads and to ensure the threads are not damaged.
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♦ Always renew self-locking bolts and nuts.
or
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3. Repair instructions 7
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4 Technical data
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4.1 Allocation gearbox - engine
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spec
es, in part or in w
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4.1.1 Golf SV 2015 ►
Take account of the gearbox code if spare parts are required for
rrectness of i
a repair.
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Dual clutch gearbox 0GC, front-wheel drive
Codes RAU, SKZ, SWU
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Engine 2.0 l - 110 kW TDI

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tion in
4.1.2 Golf 2017 ►
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If genuine parts are required for a repair, always refer to the gear‐
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box code.
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Dual clutch gearbox 0GC »front-wheel drive« t. Cop py
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Codes RAU, SKZ, SWU yri
RAU, SKZ, SWU RMV, TDG, THZ, TSX
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Engine 2.0 l - 110 kW TDI 2.0 l - 135 kW TDI
cted
2.0 I - 180 kW TSI
agen
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Dual clutch gearbox 0GC »all-wheel drive«

Codes SWR
4.1.3 Golf Estate 2017 ►

box code.
Dual clutch gearbox 0GC »front-wheel drive«
Codes RAU, SKZ, SWU RAU, SKZ, SWU

Codes RAV, SKY, SWR SWR
4.1.4 Golf SV 2018 ►

Take account of the gearbox code if spare parts are required for
a repair.
Dual clutch gearbox 0GC, front-wheel drive
Codes SWU, TNV, TDH

4.1.5 Tiguan 2016 ►

box code.
Dual clutch gearbox 0GC »front-wheel drive«
Codes SUL, UAY SWL, UBC
Engine 2.0 l - 110 kW TDI 1.5 I - 110 kW TSI

Codes SUK, UAJ TDE, UAM
Engine 2.0 l - 110 kW TDI 2.0 I - 140 kW TSI
4.2 Capacities
⇒ “4.2.1 Capacities - dual clutch gearbox”, page 9
olkswagen AG
en AG. V
⇒ “4.2.2 Capacities, front differential lock”,
olks page 9
wag does
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⇒ “4.2.3 Capacities, bevel box”, page
ris
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4.2.1 Capacities - dual clutch gearbox ss c
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Capacity Dual clutch gearbox 0GC
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Initial filling 6.8 l ± 0.1 l
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Changing approx. 6 l
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♦ Change interval: ⇒ Maintenance manual and/
h re
ole,
or ⇒ service tables “ELSA”

spec
Lubricant Dual clutch gearbox oil t to the co

rrectne
The oil is available as a replacement part; part no. ⇒ Electronic

parts catalogue (ETKA) .
ss o
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4.2.2 Capacities, front differential lock

inform
mer
Capacity of front dif‐

atio
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ferential lock
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Capacity approx. 0.60 l

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Change capacity ap‐ 0.40 l

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• Change intervals:
t.
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⇒ Maintenance C py
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4.2.3 Capacities, bevel box

Capacity Front bevel box
Initial filling approx. 0.85 l
Changing Filled for life, no change
Lubricant Gear oil
4. Technical data 9

Further information in the part number designates the container
size.
AG. Volkswagen AG d
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5 Electrical components
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5.1 Overview of fitting locations - electrical

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components
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⇒ “5.1.1 Overview of fitting locations - gearbox control”,
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page 11
spec
es, in part or in w
⇒ “5.1.2 Overview of fitting locations – electrical components,
t to the co
front differential lock”, page 12
5.1.1 Overview of fitting locations - gearbox control
rrectness of i
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1 - Mechatronic unit for dual

clutch gearbox - J743-
nform
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❑ Removing and installing

m
⇒ page 31
a
com
tion in
2 - Gearbox input speed send‐
r
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thi
er - G182- and oil temperature
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sender in multi-plate clutch -
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❑ Not for this model
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3 - Selector lever - E313- rig ht
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sors control unit - J587- ,
Prote AG.
selector lever lock sole‐

noid - N110- and selec‐
tor lever locked in posi‐
tion P switch - F319-
❑ The components are in‐
tegrated into the printed
circuit of the selector
mechanism and cannot
be renewed separately
❑ Checking ⇒ vehicle di‐
agnostic tester
selector mechanism
⇒ page 58
5. Electrical components 11
5.1.2 Overview of fitting locations – electrical components, front differential lock
1 - Transverse lock-up control

unit - J647- AG. Volkswagen AG d
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❑ Installed in lower area of ed by
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front differential lock. horis nte
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❑ Transverse lock-up con‐ ss a ra
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trol unit - J647- receives
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important signals from
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engine control unit and
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control unit for ABS with
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2 - Pump for front differential
spec
lock - V181-
t to the co
❑ Installed in lower area of
front differential lock.
❑ Can be checked using
rrectne
“guided fault finding” of
vehicle diagnosis, test‐
ss
ing and information sys‐
o
cial p
f
tem - VAS 5051- .
inform
mer
3 - Diagnostic connection
atio
m
❑ Location: in footwell,
o
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c
i
front left
or
n thi
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sd
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4 - Accelerator position sender

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pr
c
- G79- and accelerator position
um
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sender 2 - G185-
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C py
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⇒ Rep. gr. 20 ; Accel‐
ht
pyri by
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erator mechanism; As‐ by c lksw
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sembly overview - ac‐ Prote AG.
celerator pedal module

30 – Clutch
1 Clutch
⇒ “1.1 Assembly overview - dual clutch”, page 13
⇒ “1.2 Removing and installing clutch end cover”,
gen AG
. Vpage
olkswa13
gen AG
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⇒ “1.3 Removing dual clutch”, page
db
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⇒ “1.4 Installing dual clutch”,upage
tho 20 eo
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1.1 Assembly overview - dual clutch
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Replacement parts
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1 - Retaining ring for dual
, is n
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clutch end cover
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spec
❑ Renew after removal
es, in part or in w
t to the co
2 - Retaining ring for dual
clutch
rrectness of i
3 - Retaining ring for drive plate
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4 - Dual clutch
nf
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❑ Removing ⇒ page 17
orm
m
❑ Installing ⇒ page 20
atio
om
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c
5 - Shims
or
thi
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❑ 10 spacer rings which

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have different »thick‐
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nesses«. They are sized

f
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in 0.05 mm increments.
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❑ Thickness of spacer ring
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when installing dual Prote
cted AG.
agen
clutch.
6 - Dual clutch end cover
⇒ page 13
1.2 Removing and installing clutch end cov‐

er
Special tools and workshop equipment required
1. Clutch 13
♦ Clean assembly sleeve - T10459- before using. Do not use a

scratched sleeve.
Removing
• Cover and retaining ring must always be renewed.
– Drain gear oil ⇒ page 166 .
– Remove gearbox ⇒ page 71 .
– Secure gearbox in a vertical position on engine and gearbox
support ⇒ page 157 .
– Renew gear oil filter ⇒ page 163 .
AG. Volkswagen AG d
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– Lever out retaining ring -2- of clutch end cover using screw‐ y Volksw not
gu
driver -1- -arrow- and remove. ise
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es, in part or in w
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14 Rep. gr.30 - Clutch

– Lever off clutch end cover -2- through side opening in housing
using a screwdriver -1- or tyre lever -arrow- and remove clutch
end cover.
• The original clutch end cover and circlip must not be re-instal‐
led after removal.
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!
– Only handle cover as shown -in this picture-. n AG. Volkswagen AG do

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Note ir se tee
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There must be no stickers on the inside of the cover. If, however,
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stickers are present, remove them carefully.

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ility
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es, in part or in w
t to the co
– The running surface on the end of the shaft of the clutch

-arrow- must be free of oil and dry.
rrectness of i
– If necessary, thoroughly clean running surface.

l purpos
WARNING
nf
ercia
orm
The centre seal of the new cover must be »preformed« before

m
atio
m
installing:
o
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or c
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Prote AG.
1. Clutch 15
– Clean assembly sleeve - T10459- “before using”. Do not use

a scratched sleeve.
– Set sleeve on a flat surface.
– Guide cover horizontally and evenly over entire sleeve

-as shown in this figure-. This will bring the sealing lip into in‐
stallation position.
– Remove sleeve upwards out of cover and set sleeve on end
of clutch shaft.
– Moisten outer seal of cover with oil.
Caution
Moisten only the outer seal of the cover with oil. Oiling the inner
seal will always cause leaks.
AG. Volkswagen AG d
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– Guide cover horizontally over sleeve and press evenly onto its
nl
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seat.
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Caution
wit
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hole
Work carefully. Any sort of blow to the cover is certain to cause

spec
leaks.
es, in part or in w
t to the co
rrectness of i
l purpos
It is possible to lever cover carefully into its seat with a

nform
ercia
-screwdriver- until »new« retaining ring can be installed.

m
at
om
– Install new retaining ring.

ion
c
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or
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ate
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for
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AG. Volkswagen AG d
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d by ara
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Golf 2017
ut
ho ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan e o 2018 ➤ , Golf Varia ...
ra
a
ss 7-speed dual clutch gearbox 0GC c - Edition 07.2018
ce
e
nl
pt
du
an
– Do not remove bush until retaining ring is installed.
itte
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– Installing gearbox ⇒ page 150
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– Top up gear oil ⇒ page 171 .
, is n
h re
hole
spec
WARNING
es, in part or in w
t to the co
Do not start engine if there is no oil in gearbox.
rrectness of i
– After installation of gearbox, initiate default settings by
l purpos
means of Guided Functions ⇒ vehicle diagnostic tester .
nform
ercia
1.3 Removing dual clutch

m
at
om
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♦ 2 x hooks - 3438-
at
do
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for
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Cop py
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by c lksw
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Prote AG.
♦ Puller - T10055-
♦ Puller - T10525-
Brief description
• The axial play of the clutch is readjusted during installation
procedure.
1. Clutch 17
• To remove or install clutch, gearbox must be securely attached

to an assembly stand in vertical position ⇒ page 157 . Only
this way is it possible later to adjust axial play of the clutch
without error.
Removing
– Remove clutch end cover ⇒ page 13 .
Important! Installation location of drive plate
– Check that marking on drive plate -arrow- aligns with the mark‐
ing on the outer plate carrier.
If there is no marking:
– Mark installation position of drive plate relative to periphery of
outer plate carrier with permanent marker, as shown in illus‐
tration.
• During installation, drive plate must always be repositioned at
marked position.
Note
The retaining ring is renewed together with the clutch. If the clutch
which is removed is reinstalled, the securing ring is to be used
again as well.
– Lever out retaining ring -2- of drive plate using screwdriver

-1- -arrow-.
AG. Volkswagen AG d
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spec
t to the co
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cial p
f inform
mer
atio
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Cop py
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– Apply puller - T10525- together with puller - T10055- on

splines and carefully pull drive plate off its seat -arrows-.
AG. Volkswagen AG d
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– Remove retaining ring -arrow- and save it for now.
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Note
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Do not dispose of the retaining ring yet because it will be needed
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hole
to measure axial clearance.
spec
es, in part or in w
t to the co
rrectness of i
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– Remove shim -arrow-.

nform
mercia
Caution
a
com
tion in
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Carefully remove the dual clutch. Take care that no parts fall
thi
s
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out. Therefore, do not turn the clutch over!

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– Engage 2 hooks - 3438- on opposite sides of clutch -arrow-.
1. Clutch 19
– Remove dual clutch using hooks - 3438- .

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1.4 Installing dual clutch
rrectness of i
♦ Universal dial gauge holder - VW 387-
l purpos
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at
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c
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or
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Cop py
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Prote AG.
♦ Dial gauge - VAS 6079-
♦ Retaining pins - T10524-

♦ Thrust piece - T10526-
AG. Volkswagen AG d
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♦ sThe drive plate has to remain engaged between the cteeth
s
of the outer plate carrier.
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♦ If the drive plate detaches, the plates in the dual clutch can
y li
erm
ab
shift. It may then not be possible to adjust the clutch cor‐
ility
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rectly when it is installed.
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♦ Do not lift (not even slightly) or remove plate carrier! The
ole,
plates could turn.

spec
t to the co
Brief description
rrectne
• To remove or install the clutch, the gearbox must be securely

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

inform
mer
Installing
atio
om
– Take great care when removing the dual clutch from its pack‐
n
c
i
or
age.
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te
sd
va
– Turn piston rings by hand. They must move freely and must
i
o
pr
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not bind.
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Cop py
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cted agen
Prote AG.
– Ensure that piston rings -1-, -2-, -3- and -4- are seated cor‐
rectly. The ring butts -arrows- of piston rings -1- and -3- should
align.
– The ring butts -arrows- of piston rings -2- and -4- should align
and be offset 180° to the ring butts of piston rings -1- and -3-.
1. Clutch 21
Important! Position of drive plate

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

• The retaining pin - T10524- should be held by a second me‐
chanic while the dual clutch is being inserted.
AG. Volkswagen AG d
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– Carefully insert -dual clutch-, ensuring it does not fall.
, is n
h re
hole
– If necessary, insert clutch by turning slightly.

spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
r
The dual clutch is properly fitted if there is almost no play in the

o
his
te
retaining pin - T10524- .

a
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♦ The retaining pin remains inserted until the clutch end cover op Vo
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is installed. cted agen
Prote AG.
♦ The dual clutch must now not be rotated any more, as this can
shift the position of the retaining pin - T10524- .

– Lever out retaining ring -2- of drive plate using screwdriver Volkswa
-1- -arrow-. swa
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This retaining ring will be used again. Do not dispose of it.
nl
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es, in part or in w
t to the co
rrectness of i
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nf
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– Apply puller - T10525- together with puller - T10055- on
rm
m
atio
splines and carefully pull drive plate off its seat -arrows-.
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Note
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The retaining pin - T10524- must be held by a second mechanic

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while pulling off. Cop py
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– Carefully remove drive plate from dual clutch -arrows- and
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place it on one side. Prote AG.
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!
– Temporarily install “old” retaining ring -arrow-.

Before this ring is finally disposed of, 3 measurements must be
made.
First measurement (axial play of shaft)
– Screw universal dial gauge - VW 387- to gearbox flange.
1. Clutch 23
– Set -tip of dial gauge- on input shaft.

– Set -dial gauge- to 0 with preload.
– Lift dual clutch with force -in direction of arrow- to stop using
hooks - 3438- and note measurement.
– Call this value “A”.
Note
This value will be needed later for the check measurement so

save value “A” until the last measurement has been performed.
Second measurement
• The retaining pin - T10524- remains installed! agen
AG. Volkswagen AG d
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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or
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ate
do
priv
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for
en
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Cop py
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rig ht
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Prote AG.

– Set tip of dial gauge -on hub of large plate carrier-.
Note
Tip must not sit on retaining ring.
– Set -dial gauge- to 0 with preload again.

– Lift dual clutch with force to stop and note measurement.
– Call this value “B”.
Now calculate which shim must be fitted:
– Use this formula:
Value “B” minus value “A” minus 0.11 = thickness of shim to
be fitted.
– Note result.
The shims are sized in 0.05 mm increments.
– Measure the shims and determine which one is closest to the
result.
WARNING
Always use the next-largest shim, never the next-smallest.
Example:
Volkswagen AG
Calculated dimension for shimswagen AG. New shimdoes
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1.28 mm sed by 1.3 mm ara
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1.26 mm ho 1.3 mm eo
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– Remove old retaining ring -arrow-.

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ility
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Note
wit
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Do not dispose of ring yet; it will be needed once more.

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
– Fit calculated shim.

mercia
Third measurement (check measurement)

at
om
ion
c
To make sure that the shim is correct, a test measurement must

in t
or
still be carried out. Proceed as follows:

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ate
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• The retaining pin - T10524- remains installed!

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1. Clutch 25
– Install old retaining ring -arrow- once more.
– Set tip of dial gauge -on hub of large plate carrier-.
Note n AG. Volkswagen AG do

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Set the tip of the dial gauge on the shim -1-. ir se
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– Set -dial gauge- to 0 with preload again. ss
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– Lift dual clutch with force to stop and note measurement.
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– Call this value “C”.
erm
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Now calculate which shim must finally be fitted:
wit
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ole,
– Use this formula:
spec
Value “C” minus value “A” = specification
t to the co
This specification must lie between 0.05 and 0.12 mm.
If the specification is not attained, then achieve the specification
rrectne
by fitting a thicker or thinner shim.
ss
– Install new retaining ring -arrow-.
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
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sd
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fo
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Cop py
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– Fit drive plate into dual clutch.

• When installing, check if marking on drive plate is aligned with
marking on outer plate carrier -arrows-. If the markings were
subsequently make,
agen
align
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– A second d bmechanic must hold retaining pin -uaT10524-
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ran in its
ise press outwards slightly.
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– Carefully
ss drive the drive plate onto its seat using press
c tool -
40-21- and a plastic hammer.
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pt
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– Install drive plate retaining ring.
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– Starting at the opening, press retaining ring in clockwise di‐
ility
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rection into its fitting position.
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ole,
• The retaining ring must be fully engaged.
spec
– Use screwdriver to check that retaining ring is correctly seated
t to the co
and engaged.
– Now remove retaining pin - T10524- from between dual clutch
rrectne
and housing.
– Install clutch end cover ⇒ page 13 .
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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fo
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Cop py
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Prote AG.
1. Clutch 27
34 – Controls, housing
1 Mechatronic unit
⇒ “1.1 Assembly overview - mechatronic unit”, page 28
⇒ “1.2 Removing and installing sump”, page 29
⇒ “1.3 Removing and installing mechatronic unit”, page 31
1.1 Assembly overview - mechatronic unit
1 - Gearbox
2 - Mechatronic unit for dual
clutch gearbox - J743-
⇒ page 31
3 - Bolt
❑ Tightening sequence
⇒ page 29
4 - Seal
5 - Bolt
❑ 8 Nm + 60°
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6 - Retaining clip rise
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❑ Renew after removal s aut ra
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7 - Sump
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⇒ page 29
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28 Rep. gr.34 - Controls, housing

Mechatronic unit for dual clutch gearbox - J743- - specified torque

and tightening sequence
• Renew bolts after removing.
– Tighten bolts in 3 stages in the sequence shown:
Stage Bolts Specified torque/turning further angle
1. -1…9- Screw in to contact by hand
2. -1…9- 8 Nm
3. -1…9- Turn 45° further
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1.2 Removing and installing sump Vo gu
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Special tools and workshop equipment required auth
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♦ Used oil collector and extractor - VAS 6622 A-
ce
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ab
ility
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ole,
spec
t to the co
rrectness o
cial p
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♦ Engine bung set - VAS 6122-
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
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co lksw
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cted agen
Prote AG.
Removing
– Move selector lever to position “P”.
Always make sure that no dirt can enter an »open« gearbox.
1. Mechatronic unit 29
Caution
Risk of damage to gearbox.

♦ Do not run engine or tow vehicle with sump removed or AG. Volkswagen AG d
when there is no gear oil in the gearbox. agen oes
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– Remove noise insulation ⇒ General body repairs,s aexterior;
u ra
c
Rep. gr. 66 ; Noise insulation; Removing and installing noise s
ce
le
insulation .
un
pt
an
d
itte
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Vehicles with petrol engine
rm
ab
pe
ility
– Remove connecting hose between charge air cooler and ot
wit
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charge air pipe ⇒ Rep. gr. 21 ; Charge air system; Assembly
h re
overview - charge air system .
hole
spec
es, in part or in w
Continued for all vehicles
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
– Remove electrical wiring and retainers from sump at front
r
te o
thi
-arrows-.
s
iva
do
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– Raise wiring in area of sump and secure it.

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Cop py
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Caution cop Vo
by lksw
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Prote AG.
Risk of damaging mechatronic unit through electrostatic dis‐
charge.
♦ Do not touch contacts of mechatronic connector with the
hand.
– To become electrostatically discharged, touch an earthed ob‐

ject by hand (without gloves).
– Release rotary locking mechanism of connector for mecha‐

tronic unit by turning in direction of starter -arrow- and pull off
connector.

– Place used oil collection and extraction unit - VAS 6622- below
gearbox.
– Remove securing clip -3-.
– Unscrew bolts -1- diagonally and remove.
– Remove sump -2-. If necessary, lightly strike sump with a rub‐
ber-headed hammer to loosen.
Installing
Install in reverse order of removal, observing the following:
• Always renew the sump, the sump bolts and the retaining clip.
• Renew O-ring -arrow- on connector for mechatronic unit for
dual clutch gearbox - J743- .
Note
G. Volkswagen AG d
When renewing the mechatronic unit for dual clutch wagegearbox -
nA oes
olks not
J743- , the O-ring will be supplied together db
with
y V the new replace‐ gu
ara
ment part. orise nte
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– Remove any oil and grease from sealing
s surface on gearbox
ce
le
housing.
un
pt
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d
itte
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rm
ab
– Bring sump -2- into position and tighten new bolts -1- diago‐
pe
ility
nally in several stages.
ot
wit
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• When positioning the sump, ensure that no cable connections
hole
spec
are trapped.
es, in part or in w
t to the co
– Install new securing clip -3-.
• Offset side of retaining clip faces gearbox.
rrectness of i
– Fit connector for mechatronic unit and engage.
l purpos
– Top up gear oil and check gear oil level ⇒ page 166 .
Specified torques
nform
ercia
♦ ⇒ “1.1 Assembly overview - mechatronic unit”, page 28

m
a
com
tion in
1.3 Removing and installing mechatronic

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thi
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unit
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Removing
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Always make sure that no dirt can enter an »open« gearbox.
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In particular, dirt entering an »exposed« mechatronic unit and/or
co lksw
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cted agen
oil pump can lead to gearbox failure. Prote AG.
The mechatronic unit can stick on the dowel pins when the gear‐
box is very warm. Then allow the gearbox to cool down.
– Remove sump ⇒ page 29 .
– Unscrew bolts -arrows- in a diagonal sequence.

– Remove mechatronic unit -1- carefully.
lkswage es n
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ir se tee
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Holding and carrying mechatronic unit
s
ce
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un
pt
– Remove mechatronic unit for dual clutch gearbox - J743- . an
d
itte
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erm
ab
ility
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wit
is n
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ole,
spec
t to the co
rrectness o
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f inform
mer
atio
om
n
c
i
or
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sd
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Laying mechatronic unit to side properly

fo
en
ng
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– Put down mechatronic unit so that sensors -arrows- are point‐ Cop py
ing upwards.
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co
Installing
by lksw
cted agen
Prote AG.

• Renew O-ring -arrow- on connector for mechatronic unit for

dual clutch gearbox - J743- .
• Renew bolts for mechatronic unit for dual clutch gearbox -
J743- .
• When renewing the mechatronic unit for dual clutch gearbox
- J743- , the O-ring will be supplied together with the new re‐
placement part.
– Carefully insert mechatronic unit -1- into gearbox.

– Tighten bolts -arrows- of mechatronic unit for dual clutch gear‐
box - J743- ⇒ page 29 .
– Install sump ⇒ page 29 .

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– Top up gear oil and check gear oil level ⇒ page
ksw
166
agen.
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– Adopt basic setting for mechatronic unit:ised b ara
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– Connect ⇒ Vehicle diagnostic tester
s aut and start Guided Func- ra
c
tions . s
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♦ 02 Gearbox electronics
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♦ 02- Basic setting
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Specified torques
h re
ole,
spec
♦ ⇒ “1.1 Assembly overview - mechatronic unit”, page 28
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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fo
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t.
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Cop py
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rig ht
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co Vo
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Prote AG.
2 Bevel box
⇒ “2.1 Assembly overview - bevel box”, page 34
⇒ “2.2 Distinguishing between different types of bevel boxes”,
page 35
⇒ “2.3 Removing bevel box”, page 35
⇒ “2.4 Installing bevel box”, page 41
⇒ “6 Components of bevel box”, page 215
⇒ “6.2 Renewing bevel box seals”, page 219
2.1 Assembly overview - bevel box n AG. Volkswagen AG do

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1 - Bolt o
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ran
tee
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❑ Renew after removal au ac
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❑ 25 Nm
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un
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2 - Heat shield
itte
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ab
❑ For drive shaft.
ility
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❑ If present
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ole,
3 - Nut
spec
❑ Qty. 2 or 3
t to the co
❑ If present
❑ Specified torque ⇒ Run‐
rrectne
ning gear, axles, steer‐
ing; Rep. gr. 40 ; Sub‐
frame; Assembly over‐
ss
view - subframe .
o
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4 - Bolt
form
mer
❑ 40 Nm
atio
om
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5 - Heat shield
i
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❑ For propshaft.
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6 - Bolt
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❑ 20 Nm
Co
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7 - Bevel box
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Prote AG.
8 - Bolt
❑ Qty. 4
❑ Specified torque: 40 Nm
90°
9 - Bevel box carrier
❑ Different versions exist; for correct version refer to ⇒ Electronic parts catalogue (ETKA)
10 - Bolt
❑ Qty. 2
❑ Bevel box carrier to bevel box
❑ Specified torque and tightening sequence: ⇒ page 70
11 - Bolt
❑ Qty. 2

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❑ Specified torque and tightening sequence: ⇒ispage
ed
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2.2 Distinguishing between different types
nl
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Installed is either bevel box “0AV / 0FV” or bevel box “0CN”
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Bevel boxes can be identified by means of the following:
hole
spec
Area denoted by -arrow- is marked with “0AV” or “0CN”.
es, in part or in w
t to the co
Additional distinguishing feature:
The output flange on the bevel box “0AV / 0FV” is secured with a
rrectness of i
hexagon nut ⇒ Assembly overview - bevel box, “0AV / 0FV”
⇒ page 215 .
l purpos
Output flange on bevel box “0CN” is secured with a twelve-point

nut ⇒ Assembly overview - bevel box, “0CN” ⇒ page 217 .
nf
ercia
orm
For more information, refer to ⇒ Rep. gr. 34 ; Bevel box .
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om
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or c
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2.3 Removing bevel box

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ng
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♦ Socket insert - T10107 A-
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copy Vo
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cted agen
Prote AG.
♦ Counter-hold tool - T10172A-
2. Bevel box 35
♦ Engine support - T50015A-
AG. Volkswagen AG d
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♦ Bracket - T10533/2-
pt
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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
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nf
ercia
♦ Bolt - T10533/4- orm

m
atio
♦ Hexagon key extension, 8 mm - 3247-

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Cop py
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Prote AG.
♦ Torque wrench - V.A.G 1331-
♦ Flange bolt M8 x 30 mm
♦ Grease for clutch plate splines ⇒ Electronic Parts Catalogue
(ETKA)

Removing
– Raise vehicle. All 4 supports of lifting platform must be at same
height.
Note
After loosening centre bolt, do not lower vehicle to ground again.
– Depress brake pedal to remove bolt for right drive shaft

-arrow-. (2nd mechanic).
– Remove noise insulation below engine and gearbox. ⇒ Gen‐
eral body repairs, exterior; Rep. gr. 66 ; Noise insulation;
Assembly overview - noise insulation
– Separate connector -1-.

– Unscrew bolt -2- and push auxiliary pump for heating - V488-
to right side. Do not disconnect any lines ⇒ Rep. gr. 19 ;
Coolant pump, regulation of cooling system; Assembly over‐
view - electric coolant pump .
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Driveeshaft;
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olkswagen AGand installing drive shaft .
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– If fitted, remove drive shaft heat shield -1- from bevel box
erm
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-arrows- ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive

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Right drive shaft heat shield is secured with 2 or 3 nuts.

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Caution
Risk of damage to flexible joint.

rrectness of i
♦ Observe ⇒ Rep. gr. 26 ; Emission control; Assembly

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overview - emission control .

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2. Bevel box 37
– Remove clamp -2- from front exhaust pipe ⇒ Rep. gr. 26 ;

Exhaust pipes/silencers; Assembly overview - silencer .
Disregard bolts -1-.
– Unscrew bolts -arrows- on bevel box, and remove heat shield

-1-.
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– Mark position of propshaft with flexible coupling relative to
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– Unbolt front propshaft from bevel box -arrows-.

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– If necessary, counterhold at rear final drive when loosening or

tightening propshaft.
Note
Now, the propshaft is held in position solely by the centring pins

on bevel box.
– Unscrew pendulum support bolts -1- from gearbox.

– Place cloths on subframe to avoid damaging paint of propshaft
when it is placed on subframe.
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– Bolt bracket - T10533/2- -A- to engine support - T50015- -B-.

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To do this, use an M8 x 30 bolt -1-.

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– Bolt bracket -A- to gearbox using bolt - T10533/4- -C-.

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– Bolt engine support -B- to subframe using an M8 bolt.

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and radiator.
– Pull propshaft off bevel box, and lay it on subframe.
2. Bevel box 39
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– Unscrew bolts -1 and 2- and remove
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Vehicles with diesel engine
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– Unscrew bolts -A and B-, and remove gearbox carrier -1- for
bevel box.
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– Remove countersunk bolt for right flange shaft with socket - by c lksw
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T10107 A- . Prote AG.
– To do this, screw 2 bolts into flange and counterhold flange

shaft with an assembly lever.
Renew countersunk bolt after removal.

Access to the upper bolts securing the bevel box to the gearbox
may be restricted depending on engine version.
Arrangement of upper bolts (-1- and -2-) for securing bevel box
to gearbox (hidden by bevel box).
♦ Bolt -1- is located in vicinity of bolt -A-
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s securing bolts -1- and -2- for securing bevel
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– Unscrew lower bolts -arrows- securing bevel box to gearbox.
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– Carefully press off bevel box and remove.
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– Install bevel box ⇒ page 41 .
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2.4 Installing bevel box
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Note
♦ Refer to section “Removing bevel box” for required special

tools ⇒ page 35 .
♦ Renew self-locking bolts and nuts after each removal.
♦ Renew bolts that are tightened with turning further angle after
each removal.
♦ All cable ties which were opened or cut during removal must
be renewed at the same points.
♦ Lightly grease the splines of the flange shaft using grease for
clutch plate splines .
Installing
2. Bevel box 41
– Before joining bevel box and gearbox, insert “new” securing

bolts -arrows- into bevel box at top. AG. Volkswagen AG d
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– Push bevel box (with new securing bolts fitted at top) com‐ by
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pletely onto gearbox, ensuring that splines of bevel boxris input
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shaft and differential are centred when brought together.
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– If splines are correctly positioned and shafts are centred, then
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bevel box will slide to stop against gearbox.
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Note
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Do not use securing bolts to pull bevel box onto gearbox, or bevel hole
spec
box will cant and bolt holes can break off.
es, in part or in w
t to the co
Access to the upper bolts securing the bevel box to the gearbox
may be restricted depending on engine version.
rrectness of i
Arrangement of upper bolts (-1- and -2-) for securing bevel box
l purpos
to gearbox (hidden by bevel box).

♦ Bolt -1- is located in vicinity of bolt -A-
nform
mercia
♦ Bolt -2- is located in vicinity of stud with hexagon drive -B-
at
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♦ The front exhaust pipe with catalytic converter or particle filter
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or
-C- is located above the bolts.
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– Tighten upper and lower bolts -arrows- for securing bevel box
to gearbox. Specified torque: ⇒ page 70 .
– Bolt bevel box carrier to engine and bevel box, observing tight‐
ening sequence ⇒ page 70 .

Vehicles with petrol engine
Note
The next figure shows the bevel box with a splined shaft instead
of a flange shaft.
Vehicles with diesel engine
AG. Volkswagen AG d
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– Secure flangerise shaft with new countersunk bolt. Specified nte tor‐
ho eo
que: ⇒
s a Item 1 (page 34)
u t ra
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– Fit propshaft on bevel box.
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Note
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When removing and installing the bevel box, do not damage the
form
mer
seal in the propshaft flange -arrow-. Renew propshaft if damaged.

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2. Bevel box 43
– Bring bevel box and propshaft together by turning spindle of

engine support - T50015- -A-.
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– When joining parts, ensure that markings -arrows- ksw on flexible
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– Bolt propshaft to bevel box -arrows- ⇒ Propshaft and rear final
drive; Rep. gr. 39 ; Propshaft; Removing and installing prop‐
rrectness of i
shaft .
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– Bolt on heat shield -1- . Specified torque: ⇒ page 34
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AG. Volkswagen A 7-speed dual clutch gearbox 0GC - Edition 07.2018
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– Secure pendulum by support to gearbox using new t bolts
V ua -1-.
ed ran
Specified torque
horis ⇒ Rep. gr. 10 ; Assembly mountings; teeAs‐
sembly soverview
au
t
- assembly mountings or
ac
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– Fit front exhaust system to engine ⇒ Rep. gr. 26 ; Exhaust
ce
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pt
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pipes/silencers; Assembly overview - silencer .
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– Install right drive shaft ⇒ Running gear, axles, steering; Rep.
ility
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gr. 40 ; Drive shaft; Removing and installing drive shaft .
wit
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es, in part or in w
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rrectness of i
– Mount drive shaft heat shield -1-, if present, on bevel box
(-arrows-) ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive
l purpos
shaft .
Right drive shaft heat shield is secured with 2 or 3 nuts.
nf
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or
Continue installation in reverse order of removal.
m
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– Check gear oil in bevel box ⇒ page 183 .

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– Install noise insulation ⇒ General body repairs, exterior; Rep.

t
sd
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gr. 66 ; Noise insulation; Assembly overview – noise insula‐
o
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2. Bevel box 45
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⇒ “3.2 Emergency release from position P”, page 47 s
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⇒ “3.3 Removing and installing selector lever handle”,
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⇒ “3.4 Moving push-button in the handle to installation position”,
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⇒ “3.5 Removing and installing selector mechanism”, page 58
es, in part or in w
t to the co
⇒ “3.6 Removing and installing gear selector cable”, page 62
⇒ “3.7 Checking selector mechanism”, page 64
rrectness of i
⇒ “3.8 Checking and adjusting selector lever cable”, page 65
l purpos
⇒ “3.9 Renewing selector shaft seal”, page 66
3.1 Assembly overview - selector mechanism
nform
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1 - Handle with selector cover
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❑ Do not remove handle
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⇒ page 49
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2 - Bolt
❑ Qty. 4
❑ 8 Nm
3 - Selector mechanism
❑ With integrated selector
lever sensor control unit
- J587- with selector lev‐
er - E313- , Tiptronic
switch - F189- , switch
for selector lever locked
in P - F319- and selector
lever lock solenoid -
N110-
⇒ page 58
4 - Securing clip
❑ Always renew after re‐
moving.
5 - Nut
❑ Qty. 4
❑ For selector mechanism
to body
❑ 8 Nm
6 - Selector lever cable
❑ Selector lever cable is
not greased
❑ Removing and installing ⇒ page 62
❑ Checking and adjusting ⇒ page 65

AG. Volkswagen AG d
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9 - Bolt
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❑ Qty. 2
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❑ 20 Nm
spec
10 - Retaining clip
t to the co
❑ Installation position: offset side of retaining clip faces gearbox selector lever
rrectne
11 - Cable support bracket
s
❑ For selector lever cable
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12 - Grommet
form
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❑ Clip in on cable support bracket
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❑ For cable support bracket mounting on gearbox

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13 - Spacer
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❑ Installation position: larger diameter faces gearbox

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14 - Nut
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15 - Bolt
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❑ Renew after removal by c lksw
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❑ 10 Nm +90°
16 - Gearbox selector lever
3.2 Emergency release from position P

⇒ “3.2.1 Emergency release from position P, Golf 2017 ►, Golf
Variant 2017 ►”, page 47
⇒ “3.2.2 Emergency release from position P, Golf SV 2015 ►, Golf
SV 2018 ►”, page 48
⇒ “3.2.3 Emergency release from position P, Tiguan 2016 ►”,
page 49
3.2.1 Emergency release from position P,

Golf 2017 ►, Golf Variant 2017 ►
Do not remove knob.
– Using both hands, grasp into gear lever gaiter on left and right
-arrows-, and pull up selector cover -1- to unclip it.
– Depress brake pedal or set handbrake.
– Push selector cover to one side.
3. Selector mechanism 47
– Using a screw driver, from right side, press yellow plastic part
and hold in this position.
Selector lever can now be moved from position »P«.
Clip in selector cover:
Caution
The selector cover is surrounded by a chrome frame. Under

no circumstances should pressure be applied to the chrome
frame during installation. Risk of damage.
– Start by inserting selector cover -1- at rear. Then, without ap‐

plying direct pressure to chrome frame, engage it in centre
console at front.
AG. Volkswagen AG d
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3.2.2 Emergency release from position P, r nte
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Golf SV 2015 ►, Golf SV 2018 ► s a c
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Do not remove knob.
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– Using wedge - T10383- , carefully lever gear lever gaiter off
ility
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centre console insert -arrows-.
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es, in part or in w
t to the co
rrectness of i
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c
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3.2.3 Emergency wrelease

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Do not remove knob.
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– Fit wedge - T10383/2- at front between centre console and
ce
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selector cover, and lever selector cover off centre console by
pt
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carefully pushing wedge downwards.
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3.3 Removing and installing selector lever

handle
⇒ “3.3.1 Removing and installing selector lever handle, Golf
2017 ►, Golf Estate 2017 ►”, page 49
⇒ “3.3.2 Removing and installing selector lever handle, Golf SV
2015 ►, Golf SV 2018 ►”, page 52
⇒ “3.3.3 Removing and installing selector lever handle, Tiguan
2016 ►”, page 54
3.3.1 Removing and installing selector lever

handle, Golf 2017 ►, Golf Estate 2017 ►
♦ Hose clip pliers - V.A.G 1275 A-
Brief description
Handle is removed together with selector cover.
Removing
– Using both hands, grasp into gear lever gaiter on left and right
-arrows-, and pull up selector cover -1- to unclip it.
– Separate electrical connector.
– Cut open clamp -arrow- under boot using side cutters.
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Pull off handle upwards without pressing push button -arrow-.

Push button engages automatically in installation position when
handle is pulled off.
rrectness of i
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Note
nform
ercia
Do not press button again after removal as it will otherwise no

longer be possible to install the handle.
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• Selector lever is in position “D”.

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Note
♦ It might be possible for the button to be pressed into the han‐

dle. Never install a handle with the button pressed in.
♦ Move push-button to installation position ⇒ page 57 .
♦ New handle is supplied with installation guard. Do not remove
guard until just before installing. To remove, pull out
-in direction of arrow-.
A n AG d G. Volkswage
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– Push handle fully onto
Voselector
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Handle with clamp: s
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– Push on handle with new clamp -arrow- to stop.

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– Secure clip with hose clip pliers - V.A.G 1275 A- .

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– Connect electrical connector.

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– Push button after installation.

spec
es, in part or in w
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Note
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If not installed correctly, the button remains inserted in the handle

after being pressed. If this happens, remove handle again and
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move push-button to installation position again ⇒ page 57 .

Then, fit the handle again.
nform
mercia
a
com
Caution
ion in
r
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thi
The selector cover is surrounded by a chrome frame. Under

s
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do
no circumstances should pressure be applied to the chrome

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frame during installation. Risk of damage.

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– Start by inserting selector cover -1- at rear. Then, without ap‐

plying direct pressure to chrome frame, engage it in centre AG. Volkswagen AG d
console at front. agen oes
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handle, Golf SV 2015 ►, Golf SV 2018 ►
rrectness of i
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♦ Hose clip pliers - V.A.G 1275 A-
nform
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c
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♦ Wedges - T10383-
Brief description

Removing
– Using wedge - T10383- , carefully lever gear lever gaiter off
centre console insert -arrows-.
G. Volkswagen AG d
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es, in part or in w
t to the co
rrectness of i
– Push handle fully onto selector lever and lock.
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– Push sleeve downwards to lock.

nform
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Handle with clamp:

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– Push on handle with new clamp -arrow- to stop.

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– Secure clip with hose clip pliers - V.A.G 1275 A- .

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after being pressed. If this happens, remove handle again and
move push-button to installation position again ⇒ page 57 .
– Clip cover in position.

handle, Tiguan 2016 ►

♦ Hose clip pliers - V.A.G 1275-
♦ -T10383/2-
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Removing
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– Shift selector lever to position “D”.

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The push button -arrow- does not need to be pulled out by hand.
Push button engages automatically in installation position when
rrectne
handle is pulled off.

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– Fit wedge - T10383/2- at front between centre console and C py
ht. rig
selector cover, and lever selector cover off centre console by rig ht
py by
carefully pushing wedge downwards.
co Vo
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– Pull handle upwards off selector lever without pressing push
button.
Note
Do not press button again after removal as it will no longer be

possible to install the handle.
Installing
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– Push on handle with new clamp -arrow- to stop. Do not tighten

clamp yet.
Note

after being pressed. If this happens, pull handle off again and
move push button to installation position again ⇒ page 57 .
– If the press button moves back to its start position, the clamp
can be tightened using the hose clip pliers - V.A.G 1275- .
– Clip cover in position.
3.4 Moving push-button in the handle to in‐

stallation position
If the button was pressed by mistake, the installation position
AG. Vocan
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be restored. swagen does
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There are 2 ways of moving the push-button ris into the installation
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Place handle »with« installation guard in installation position:
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When using the installation guard, make sure that it has an eyelet
erm
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-arrow- at the front. Other types of installation guard are not suit‐
ility
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able.
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– Holding down push button, completely push in installation

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

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

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the push-button engages in the installation position.

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Place handle »without« installation guard in installation position:

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Cop py
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– Carefully unclip handle trim -A- upwards.
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rrectness of i
– Using e.g. a screwdriver press small lever -1- for pull rod into
groove -2-. This action presses the push button -3- back into
l purpos
installation position.
-I- = button pressed in
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-II- = button in installation position

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♦ Only press the lever into the groove and no further.

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♦ Do not clip the handle trim onto selector mechanism until the Cop py
handle has been fitted. This makes it possible to check wheth‐
t. rig
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er the small lever engages in the pull rod when the push-button cop Vo
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is pressed. cted agen
Prote AG.
3.5 Removing and installing selector mech‐

anism
⇒ “3.5.1 Removing and installing selector mechanism with selec‐
tor lever cable”, page 58
⇒ “3.5.2 Removing and installing selector mechanism without se‐
lector lever cable”, page 60
3.5.1 Removing and installing selector mech‐

anism with selector lever cable

♦ Release lever - 80-200-
Brief description
In the interior, the centre console must be removed.
The heat shield beneath the vehicle must be removed.
Removing
– Remove selector lever handle ⇒ page 49 .
– Remove centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; Centre console; Removing and installing centre con‐
sole .
– If fitted, remove footwell air duct ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air duct; Assembly overview - air routing and air
distribution in passenger compartment .
– Separate electrical connector from selector mechanism to ve‐
hicle wiring harness.
– Remove air filter housing ⇒ Rep. gr. 23 ; Air filter; Removing
and installing air filter housing
. Volkswagen AG
– Push ball socket -1- of selector lever cable off gearbox kselector
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lever using removal lever - 80-200- . by
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– Unscrew bolts -2- for cable support bracket.thor eo
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– Do not bend or kink cable. ss
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nl
pt
du
– Install centre tunnel heat shield below selector mechanism ⇒

an
itte
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General body repairs, exterior; Rep. gr. 66 ; Mouldings/trims/

erm
ab
extensions; Removing and installing floor heat shield .

ility
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wit
, is n
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spec
es, in part or in w
t to the co
rrectness of i
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Cop py
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– Remove bracket -A- if present.

– Remove nuts -arrows- inside vehicle.
– Remove selector mechanism -B- together with selector lever
cable and selector housing downwards. n AG. Volkswagen A age G do
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Installing by Vol ot g
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Install in reverse order of ris
removal.thoObserve the following when tee
or
doing this: ss au ac
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♦ Do not bend or kink gear selector cable.
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♦ Do not grease selector lever cable.
ole,
spec
♦ Following installation of selector mechanism, selector lever
t to the co
cable must be checked for ease of movement and be adjusted.
– Install heat shield below selector mechanism ⇒ General body
rrectne
repairs, exterior; Rep. gr. 66 ; Mouldings/trims/extensions;
Removing and installing floor heat shield .
ss
– If featured, install footwell air duct ⇒ Heating, air conditioning;
o
cial p
f i
nform
mer
atio
m
– Install centre console ⇒ General body repairs, interior; Rep.

o
n
c
i
or
n thi
e
sole .
t
sd
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pr
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– Install selector lever handle ⇒ page 49 .
um
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fo
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– Adjust selector lever cable ⇒ page 65 .
Co
Cop py
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– Check selector mechanism ⇒ page 64 .
ht
pyri by
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– Install air filter housing ⇒ Rep. gr. 23 ; Air filter; Removing
cted agen
Prote AG.
and installing air filter housing .
Specified torques
♦ Selector housing to body ⇒ page 46
3.5.2 Removing and installing selector mech‐

anism without selector lever cable
Brief description
In the interior, the centre console must be removed.
The heat shield beneath the vehicle must be removed.
Removing
– Remove selector lever handle ⇒ page 49 .
– Remove centre console ⇒ General body repairs, interior; Rep.
sole .
– If fitted, remove footwell air duct ⇒ Heating, air conditioning;
– Separate electrical connector from selector mechanism to ve‐
hicle wiring harness.
– Shift selector lever on selector mechanism to position “N”.


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

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

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

Always renew securing clip.
AG. Volkswagen AG d
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– Pull selector lever cable out of selector mechanism.
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Cop py
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pyri by
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– Remove bracket -A- if present.

– Remove nuts -arrows- inside vehicle.
– Remove selector mechanism -B- together with selector hous‐
ing downwards.
Installing
Install in reverse order of removal. Observe the following when
doing this:
Note

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♦ Following installation of selector mechanism, selector
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cable must be checked for ease of movement band y V be adjusted.
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• Selector lever on selector mechanisms a must be set to position
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“N”. s
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– Insert cable into selector mechanism, attach to selector lever
an
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and fit new securing clip.
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– If featured, install footwell air duct ⇒ Heating, air conditioning;
t to the co
– Install centre console ⇒ General body repairs, interior; Rep.
rrectness of i
l purpos
sole .
– Install selector lever handle ⇒ page 49 .
nform
ercia

m
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ti

on in
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Specified torques
s
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♦ Selector housing to body ⇒ page 46

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3.6 Removing and installing gear selector
C py
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cable
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Removing
– Push ball socket -1- of selector lever cable off gearbox selector
lever using removal lever - 80-200- .
– Unscrew bolts -2- for cable support bracket.
– Do not bend or kink cable.
– Shift selector lever on selector mechanism to position “N”. On‐
ly in this position the selector lever cable can be released.
– Using a screwdriver lever the cover off from nunder

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It is not permissible to reuse the cover. Always renew after re‐
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– Release the cable as shown with a screwdriver, and pull off
from the selector lever -arrows-.
rrectness of i
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Cop py
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– Remove securing clip -arrow-.

Always renew securing clip.
– Pull cable out of selector mechanism and remove.
Installing
doing this:
Note

AG. Volkswagen AG d
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♦ Following installation, selector lever cable must
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obe checked
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• Selector lever on selector mechanism
ss must be set to position c
“N”.
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nl
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du
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– Insert cable into selector mechanism, attach to selector lever
y li
erm
ab
and fit new securing clip.
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hole
spec
es, in part or in w
t to the co
– Bring selector lever cable with cable support bracket into po‐
sition and tighten with bolts -2-.
rrectness of i
– Do not press ball head -1- of selector lever cable onto gearbox
selector lever yet. Wait until selector lever cable has been
l purpos
checked and adjusted.

– Check and adjust selector lever cable ⇒ page 65 .
nform
ercia

m
at
om
io
n
c
in t
or

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ate
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Continue installation in reverse order of removal.

p
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3.7 Checking selector mechanism Cop py
t. rig
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The starter must not operate in the selector lever positions “R”,
cop Vo
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cted
“D” and “S” and in the Tiptronic position.
agen
Prote AG.
On right-hand drive vehicles, the starter must operate in selector

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

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

when the push-button is pressed. Solenoid for selector lever lock
blocks selector lever.
• Brake pedal is depressed:
Solenoid for selector lever lock releases selector lever. It is pos‐
sible to shift into a driving gear. Slowly shift selector lever from
“P” through to “S”, checking whether selector lever position in
dash panel insert corresponds to selector lever position.
Selector lever in “N” position and ignition switched on
• Brake pedal not depressed:
Selector lever is locked and cannot be shifted out of “N” position
with the push-button pressed. Solenoid for selector lever lock
blocks selector lever.
• Brake pedal is depressed:
Solenoid for selector lever lock releases selector lever. It is pos‐
sible to shift into a driving gear.
Selector lever in position “Tiptronic”
• Shift selector lever into Tiptronic gate.
The illumination of the “D” symbol in the selector mechanism cov‐
er must go out. “+” and “-” symbols must light up.
When the selector lever is shifted into the Tiptronic gate, the se‐
lector lever position display in the dash panel insert must change
from “P R N D S” to “6 5 4 3 2 1”.
Ignition and light switched on
The respective symbol in the shift mechanism cover lights up.
Selector lever position indicator AG. Volkswagen AG d
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Simultaneous illumination of all selector lever position display
ed b ara
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is
segments indicates gearbox emergency running mode. hor eo
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3.8 Checking and adjusting selector lever s
ce
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nl
pt
cable
du
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itte
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ab
ility
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
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e
Brief description
at
do
priv
Selector lever cable must be removed from gearbox so that its

um
for
en
ease of movement can be checked. Put removed end down so it

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does not rub against anything. t. Cop py
rig
gh ht
Then the selector lever must be moved and after that, the Bowden pyri by
Vo
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by c
cable must be reattached to the gearbox.
lksw
cted agen
Prote AG.
Then the selector lever cable must be adjusted.
Do not grease connections of cable!

Always adjust selector lever cable if the following applies:
♦ The selector lever cable has been removed from the gearbox.
♦ The engine and/or gearbox has been removed and installed.
♦ Parts of the assembly mounting have been removed and in‐
stalled.
♦ The cable itself or the selector mechanism has been removed
and installed.
♦ The position of the engine and gearbox is shifted, for example
to install it free of tension.
AG. Volkswagen AG d
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not
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• Air filter housing is removed. ised⇒b Rep. gr. 23 ; Air filter; Re‐ ara
nte
moving and installing airuthfilter
o r
housing eo
a ra
s c
– Switch selector lever sto “P” position.
ce
le
un
pt
an
d
itte
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erm
ab
ility
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– Shift selector lever several times from position »P« to »S« and
wit
is n
back to »P«.
h re
ole,
• Selector lever must move easily.
spec
t to the co
Adjusting
– Move selector lever in vehicle to “P” position.
rrectne
– Selector shaft on gearbox is also in position “P”. To check,
push lever opposite to driving direction to rear stop.
ss o
cial p
f in
Note
form
mer
atio
m
Raise vehicle, to be sure that the gearbox is in “P” (parking lock

o
n
c
engaged). It should not be possible to turn both front wheels to‐

i
or
n thi
gether in the same direction.

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sd
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ng
– Loosen adjustment screw -arrow- for selector lever cable.

t.
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Cop py
– Gently push knob of selector lever forwards and backwards
t. rig
gh ht
yri
but under no circumstances must you shift out of “P”.
p by
o Vo
by c lksw
cted agen
– Tighten bolt -arrow- to 15 Nm.
Prote AG.
This completes the adjustment.

– Install air filter housing.
– ⇒ Rep. gr. 23 ; Air filter; Removing and installing air filter
housing
3.9 Renewing selector shaft seal

Brief description
The seal can be renewed only with the gearbox removed.

♦ Tube - VW 423-
AG. Volkswagen AG d
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♦ Extractor hook - T20143- s
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ility
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spec
es, in part or in w
t to the co
rrectness of i
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♦ Not illustrated: Torque wrench - V.A.G 1331-

nf
ercia
Sequence of operations
rm
m
atio
m
• Gearbox is installed.
o
n in
or c
thi
• Renew bolts that are tightened with turning further angle after
te
sd
a
each removal.
iv
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r
rp
cu
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m
f
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;

en
ng
t.
yi
Removing and installing battery .
Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
– Unscrew bolt -arrow- and remove gearbox selector lever -1-.
– Lever out seal using extractor hook - T20143/1- -arrow-.
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– Apply gear oil to circumference and sealing lips of new oil seal.
itte
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erm
ab
– Fill half of the space between sealing lip and dust lip -arrow-
ility
ot p
with sealing grease ⇒ Electronic parts catalogue .

wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
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or
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cted agen
68
Prote AG.
Rep. gr.34 - Controls, housing
– Drive in seal to stop with tube - VW423- , being careful not to

cant seal.
Volkswagen AG
• Closed side of oil seal -arrow- faces towards outside.swagen AG. does
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hole
spec
– Place gearbox selector lever -1- on shaft for parking lock and
es, in part or in w
t to the co
tighten bolt -arrow-.
– Push selector lever onto gearbox selector lever, and adjust
selector lever cable ⇒ page 65 .
rrectness of i
– Install battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
l purpos
Removing and installing battery tray .

Specified torques
nf
ercia
orm
♦ ⇒ “3.1 Assembly overview - selector mechanism”, page 46
m
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om
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or c
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Prote AG.
4 Removing and installing gearbox

⇒ “4.1 Specified torques for gearbox”, page 70
⇒ “4.2 Removing gearbox”, page 71
⇒ “4.3 Installing gearbox”, page 150
4.1 Specified torques for gearbox

Item Bolt Nm
. Volkswagen AG
1, 2, 3 M12x55 gen AG
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4 M12x65 80
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5, 6, 7 M10x50 40
ility
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8, 9 M12×70 80
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A Dowel sleeves for centring
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spec
es, in part or in w
t to the co
Component Nm
Assembly mountings to gearbox (renew bolts after 60 Nm + turn 90° further
each removal)
rrectness of i
Earth strap to assembly mounting 25
l purpos
Heat shield for right drive shaft to bevel box 20

Propshaft to bevel box ⇒ Rep. gr. 39 ; Propshaft; Assembly overview - prop‐
nform
ercia
shaft
m
at
om
ion
c
in t
or
his
te
Bevel box to gearbox

a
do
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or
Bevel box to gearbox ⇒ “2.1 Assembly overview - bevel

f
en
ng
t.
♦ Renew bolts after re‐ box”, page 34
yi Co
op
moving.
C py
t. rig
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pyri by
Vo
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by c lksw
4.1.1 Gearbox carrier to engine and bevel box
cted agen
Prote AG.
Installation location and tightening sequence:

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

1. -1- and -2- Screw in to contact by hand
2. Tighten -2- 40 Nm
3. Tighten -1- 40 Nm

Diesel engine
Item Bolt
A M10 x 21
B M10 x 45
Sequence Bolts Specified torque

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

♦ Bolt -A-: 20 Nm
♦ Bolt -B-: 40 Nm
4.2 Removing gearbox

⇒ “4.2.1 Removing gearbox, Golf SV 2015 ►, Golf SV 2018 ►,
vehicles with diesel engine, front-wheel drive”, page 71
agen
AG. Volkswagen AG d
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olks ot g
⇒ “4.2.2 Removing gearbox, Golf 2017 ►, Golf ed
bEstate
yV 2017 ►, ua
ran
vehicles with diesel engine, front-wheel drive”,
h oris page 83 tee
t or
au ac
⇒ “4.2.3 Removing gearbox, Golf 2017ss ►, Golf Estate 2017 ►,
vehicles with diesel engine, all-wheel drive”, page 97
ce
e
nl
pt
du
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itte
⇒ “4.2.4 Removing gearbox, Golf 2017 ►, vehicles with petrol en‐

y li
erm
ab
gine”, page 108
ility
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⇒ “4.2.5 Removing gearbox, Tiguan 2016 ►, vehicles with diesel

wit
, is n
h re
engine, all-wheel drive”, page 118

hole
spec
⇒ “4.2.6 Removing gearbox, Tiguan 2016 ►, vehicles with diesel

es, in part or in w
engine, front-wheel drive”, page 128

t to the co
⇒ “4.2.7 Removing gearbox, Tiguan 2016 ►, vehicles with 1.5 l

petrol engine, front-wheel drive”, page 135
rrectness of i
⇒ “4.2.8 Removing gearbox, Tiguan 2016 ►, vehicles with 2.0 l

l purpos
petrol engine, all-wheel drive”, page 141
4.2.1 Removing gearbox, Golf SV 2015 ►,

nf
ercia
or
Golf SV 2018 ►, vehicles with diesel en‐

m
m
atio
m
gine, front-wheel drive

o
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Brief description
t
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The gearbox is removed downwards separately. The engine re‐

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mains in the vehicle.

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Battery, battery carrier and air cleaner housing are removed
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»from above«. Engine and gearbox must then be supported so cop Vo
by lksw
that left assembly mounting can be detached. cted agen
Prote AG.
»From below«
4. Removing and installing gearbox 71

n AG. Volkswagen A
Pendulum support and left drive olks
wshaft
age removed. Right drive
G do
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remains installed in wheeld bbearing
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swivelled to one side. orise
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The subframe remains
ss
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in the vehicle. ac
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Special tools and workshop
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equipment required
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Cop py
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♦ Support - 10 - 222 A-
♦ Adapter - 10 - 222 A /29-
♦ Adapter - 10 - 222 A /18-
♦ Shackle - 10 - 222 A /12-
♦ Pin - 3282/29-
♦ Gearbox support - 3282-

♦ Engine and gearbox jack - VAS 6931-
♦ Adjustment plate - 3282/61-
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♦ Hose clamps to 25 mm - 3094-
h re
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♦ Tensioning strap - T10038-

at
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Cop py
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rig ht
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♦ Release lever - 80 - 200-

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♦ Insert tool, 18 mm - T10179-

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Cop py
♦ Multi-point bit - T10061- ht. rig
rig ht
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co Vo
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cted agen
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7-speed horisdual clutch gearbox 0GC - Edition 07.2018nte
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♦ Adapter - 10 - 222 A /3-
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tion in
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te o
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Cop py
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rig ht
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by lksw
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Prote AG.
♦ Bracket - T10346/1-
Removing
height.
– Switch selector lever to »P« position.
Note

– Depress brake pedal to remove bolt for left drive shaft

-arrow- (second mechanic required).
– Remove engine cover panel ⇒ Rep. gr. 10 ; Engine cover
panel; Removing and installing engine cover panel .
– Pull off bleeder connection -1-, if fitted, with breather hose from
locking mechanism -arrow- of battery tray -3-.
– Remove battery with battery tray ⇒ Electrical system; Rep.
gr. 27 ; Battery; Removing and installing battery tray .
AG. Volkswagen AG d
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– Remove bolts -arrows- ility
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wit
– Open screw-type clip -3- and remove charge air pipe -1- ⇒
is n
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Rep. gr. 21 ; Charge air system; Assembly overview - charge

ole,
spec
air system .
t to the co
Disregard screw-type clip -2-.

rrectness o
cial p
f inform
mer
atio
m
– Lever off selector lever cable -1- from gearbox selector lever
o
n
c
using removal lever - 80 - 200- .

i
or
n thi
te
sd
a
– Unscrew bolts -2-, raise and tie cable support bracket -3- to‐
iv
o
pr
gether with selector lever cable.

um
r
fo
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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cted agen
Prote AG.

7-speed dual clutch
gen AG
. Volkgearbox
swagen AG0GC - Edition 07.2018
d wa oes
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♦ On a warm engine, the cooling system is under high pressure.
nl
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du
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itte
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♦ Before removing the coolant hoses on the gearbox, cover the
erm
ab
cap -arrow- on the coolant expansion tank with a cloth and
ility
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open carefully.
wit
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hole
– Lay lint-free cloths on gear oil cooler and gearbox to catch
spec
es, in part or in w
escaping coolant.
t to the co
rrectness of i
– Clamp off coolant hoses using hose clamps to 25 mm - 3094-
and disconnect hoses from gear oil cooler.
l purpos
nform
mercia
at
om
ion
c
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or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co
– Release rotary fastener of connector for mechatronic unit -1-
by lksw
cted agen
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by turning in direction of starter and pull off connector.
AG.
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;

Removing and installing starter .
– Remove charge air line. ⇒ Rep. gr. 21 ; Charge air system;
Assembly overview - charge air system
– Unscrew upper engine/gearbox connecting bolts using insert

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

A bolt is located in the starter motor hole -arrow-. This bolt can be
removed using socket - T10061- .
– If there are hoses and cable connections in area of engine
support eye for support bracket - 10 - 222 A- , remove these
now.
– Install support bracket - 10-222 A- as follows:
Required material:
♦ Adapter - 10 - 222 A /3-
♦ Adapter - 10 - 222 A /18-
♦ Shackle - 10 - 222 A /12- (required when spindle of engine
support bracket cannot be hooked into lifting eye of engine).
♦ Adapter - 10 - 222 A /29- , qty. 2
– On both sides of vehicle, insert adapters - 10 - 222 A /29- be‐

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

vehicle.
Arrow -2- always points in direction of travel.
• Fit adapters - 10 - 222 A /29- directly onto the outer edge,

which faces towards wing -arrows-.
The adapter on the “right” side of the vehicle is engaged in the AG. Volkswagen AG d
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t to the co
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cial p
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mer
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Cop py
t. rig
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Golf 2017 ➤ , Golf Sportsvan
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tee Varia ...
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ac
ss
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– Push adapter - 10 - 222 A /18- and adapter - 10 - 222 A /3-
pt
an
d
itte
onto support bracket - 10-222 A- .
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ab
pe
– Secure support bracket - 10-222 A- to adapters - 10 - 222 A /
ility
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29- .
wit
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es, in part or in w
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tion in
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• Secure both adapters - 10 - 222 A /29- with tensioning straps
en
ng
t.
- T10038- . Cop
yi Co
py
t. rig
• The tensioning strap - T10038- must be attached in recess gh ht
yri by
-arrow- in bonnet hinge. cop Vo
by lksw
cted agen
Prote AG.
– Then, attach spindles in engine lifting eyes.
– Take up weight of engine/gearbox assembly and support
bracket on spindles .
– Remove noise insulation ⇒ General body repairs, exterior;
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 .
Vehicles with window washer system:
– Detach nut -3- from washer fluid reservoir -4- ⇒ Electrical

system; Rep. gr. 92 ; Windscreen washer system; Removing
and installing washer fluid reservoir .
This will allow for pushing washer fluid reservoir aside slightly at
a later stage when removing the gearbox.
1) Disregard bolts -1 and 2-.
Continuation for all:


-arrows-.
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ility
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– Release electrical connector for auxiliary hydraulic pump 1 for
h re
hole
gearbox oil - V475- -a- and pull off connector -b-.
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
e
– Detach connector -1- from oil level and oil temperature sender
at
do
riv
- G266- , if fitted.
p
cum
for
en
g
– Remove left drive shaft ⇒ Running gear, axles, steering; Rep.

n
t.
yi Co
gr. 40 ; Drive shaft; Removing and installing drive shafts . Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– If fitted, remove heat shield for right drive shaft -arrows- ⇒

Running gear, axles, steering; Rep. gr. 40 ; Drive shaft; Re‐
moving and installing drive shaft heat shield .
– Remove right drive shaft from gearbox. ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Drive shaft; Removing and in‐
stalling drive shaft .

– Use tensioning strap - T10038- to secure drive shafts on sus‐

pension strut.
The surface protection of the shafts must not be damaged.
en AG . Volkswag
– Remove clamp -2- for exhaust ksw
agensystem from engine
AG doesthen raise
not
and tie front exhaustbpipe
y V ⇒ Rep. gr. 26 ; Exhaust pipes/
ol
gu
ara
silencers; Assembly
ris overview - silencer .
ed
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Disregard boltsss-1-.
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ility
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t to the co
– Remove pendulum support. First remove bolt -1-, followed by
bolts -2- and -3-.
– Remove all but one »easily accessible« connecting bolt be‐ rrectnes
tween engine and gearbox from underneath.
s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
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fo
en
ng
t.
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Cop py
.
– Remove bolts -arrows- of assembly mounting for gearbox.
ht rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

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

engine/gearbox »only« on gearbox side as far as dimension
-a-. AG. Volkswagen AG d
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lksw not
Dimension -a- = about 80mm d byV
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ility
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wit
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spec
– Remove radiator cowl with radiator fan -arrow- ⇒ Rep. gr. 19 ;
es, in part or in w
t to the co
Radiator, radiator fan; Removing and installing radiator cowl .
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
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– Place protective mat between radiator and engine.
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Secure bracket - T10346/1- to subframe as shown in illustra‐

tion using an M 8 x 25 bolt -left arrow-.
– Screw engine support - T50015- to bracket - T10346/1- and to
left threaded hole for heat shield on engine block
-right arrow-. To prevent damage to oil sump, insert a spacer
-A- e.g. M12 nut between engine support and engine.
– Force engine/gearbox as far forwards as possible by turning
spindle of engine support - T50015- . Avoid collisions of com‐
ponents.

AG. Volkswagen AG d
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Golf 2017 Vol➤ , Golf Sportsvan 2015 ➤ o, t Golf
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Sportsvan 2018 ➤ , Golf Varia ...
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Gearbox support - aligned with adjustment plate - 3282-
ss is
3282/61- for removal of gearbox 0GC.
ce
e
nl
pt
du
an
itte
– Gearbox support - 3282- is inserted in engine and gearbox
y li
erm
ab
jack - VAS 6931- .
ility
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– Align arms of gearbox support according to holes in adjust‐
wit
, is n
h re
ment plate .
hole
spec
– Screw support elements -A- into adjustment plate as illustra‐
es, in part or in w
ted. Deviating from this, pin - 3282/34- is used as rear right
t to the co
support element. This support element is located outside ad‐
justment plate .
rrectness of i
• Support element -C- on adjustment plate is not used.
l purpos
– Position engine and gearbox jack - V.A.G 1383 A- with gear‐

box support - 3282- under gearbox.
nform
ercia
All gearboxes are supported as shown in the illustration.

m
at
om
io
– Mount safety support -1- and hook -2- on gearbox as shown.
n
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.
– 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.
Note
Be careful of all lines when lowering gearbox.
Transporting gearbox ⇒ page 155 .

Secure gearbox to assembly stand ⇒ page 157 .
Install gearbox ⇒ page 150 .
4.2.2 Removing gearbox, Golf 2017 ►, Golf

Estate 2017 ►, vehicles with diesel en‐
gine, front-wheel drive
Brief description
mains in the vehicle.
»from above«. Engine and gearbox must then be supported so
that left assembly mounting can be detached.
»From below«

Pendulum support and left drive shaft removed. Right drive shaft
remains installed in wheel bearing housing and only needs to be
swivelled to one side.
The subframe remains in the vehicle.
Special tools and workshop AG. Volkswagen AG d

equipment required agen oes
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es, in part or in w
t to the co
rrectness of i
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nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Support - 10 - 222 A-
♦ Adapter - 10 - 222 A /29-
♦ Not required: adapter - 10 - 222 A /18-
♦ Shackle - 10 - 222 A /12-
♦ Pin - 3282/29-

♦ Engine and gearbox

jack - VAS 6931-
♦ Adjustment plate -
3282/61-
♦ Hose clamps to 25
mm - 3094-
AG. Volkswagen AG d
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ility
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♦ Tensioning strap -
ole,
spec
T10038-
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Engine bung set -

VAS 6122-
♦ Insert tool, 18 mm -
T10179-
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d ran
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ss
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un
pt
♦ Multi-point bit -
an
d
itte
T10061-
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
♦ Adapter - 10 - 222 A /
m
3-
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.

♦ Release lever - 80 -
200-
♦ Engine support -
T50015A-
AG. Volkswagen AG d
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olksw not
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d by ara
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♦ Bracket - T10346/1- ut
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ra
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pt
du
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ab
ility
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, is n
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es, in part or in w
t to the co
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♦ Square tube -
T40091/1- , qty. 2 nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
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for
en
ng
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Cop py
t. rig
gh ht
pyri by
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by c lksw
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Prote AG.
♦ Connecting piece -
T40091/3- , qty. 2

♦ Spindle - T40093 /3-

from engine support
supplementary set -
T40093- , qty. 2
♦ Adapter -
T40093/3-6- : qty. 2
(check and modify as
necessary
⇒ page 88 )
AG. Volkswagen AG d
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♦ or adapter - d by V gu
ara
T40093/3-6A- : qty. 2 rise nte
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Check adapters - ss c
T40093/3-6- and modify
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pt
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as necessary
an
itte
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– If necessary, cut off
ility
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the marked area.
wit
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– Round off front
hole
edges.
spec
es, in part or in w
– Protect adapter t to the co

against corrosion.
– Then, mark adapters
rrectness of i
- T40093/3-6- as -
T40093/3-6A- .
l purpos
At a later point, support

bracket - 10-222 A- will
nf
ercia
be fitted onto longitudinal

rm
m
atio
members with adapters -

om
T40093/3-6A- .
n in
or c
thi
e
• To prevent damage
t
sd
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to the longitudinal
o
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cu
members, wrap the

o
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f
en
ng
front section of the

t.
yi Co
op
adapters - C py
t. rig
T40093/3-6A- with
gh ht
pyri by
textile-reinforced ad‐
co Vo
by lksw
cted agen
hesive tape ⇒ Elec‐ Prote AG.
tronic parts catalogue
(ETKA chemical sub‐
stances) .

lkswage es n
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byV ua
ed ran
Golf 2017 hor➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan
is tee 2018 ➤ , Golf Varia ...
t or
au 7-speed dual clutch gearbox 0GC
ac - Edition 07.2018
ss
ce
e
nl
Removing
pt
du
an
itte
y li
– Raise vehicle. All 4
erm
ab
supports of lifting
ility
ot p
platform must be at
wit
, is n
h re
same height.
hole
spec
– Switch selector lever
es, in part or in w
to »P« position.
t to the co
Note
rrectness of i
l purpos
After loosening centre

bolt, do not lower vehicle
to ground again.
nform
mercia
at
om
io
– Depress brake pedal to remove bolt for left drive shaft
n
c
in t
or
-arrow- (second mechanic required).
his
ate
do
riv

p
cum
or

f
en
ng
t.
yi Co
– Remove air filter housing ⇒ Rep. gr. 23 ; Air filter; Removing Cop py
t. rig
and installing air filter housing opyri
gh by
Vo
ht
c by lksw
cted agen
Prote AG.

– Remove bolts -arrows-

wage
– Open screw-type clip -3- and remove charge airVpipe olks -1- ⇒ es n
ot g
y
Rep. gr. 21 ; Charge air system; Assembly soverview
d b - charge ua
ran
ir e
air system . tho tee
or
au ac
Disregard screw-type clip -2-. ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
Note pyri by
Vo
co lksw
by
cted agen
Prote AG.
open carefully.

escaping coolant.




– Remove fuel filter and lay to side. Do not open pipe/hose sys‐
tem ⇒ Rep. gr. 20 ; Fuel filter; Assembly overview - fuel filter .
G. Volkswagen AG d
support eye for support bracket - 10 - l222
kswagA- , remove these
en A oes
not
now. by Vo gu
a d ran
ise tee
– Install support bracket - 10-222
ut
ho A- as follows:
r
or
a ac
Required material: ss
ce
e
nl
pt
du
♦ Adapter - 10 - 222 A /3-

an
itte
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erm
ab

ility
ot p

wit
, is n
h re
♦ Adapter - 10 - 222 A /29- , qty. 2

hole
spec
♦ Square tube - T40091/1-

es, in part or in w
t to the co
♦ Connector - T40091/3-
♦ Spindle - T40093 /3-
rrectness of i
♦ Check adapter - T40093/3-6- and modify as necessary

l purpos
⇒ page 88
♦ or adapter - T40093/3-6A-
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.

– On both sides of vehicle, insert adapters - 10 - 222 A /29- be‐wagen AG. Volkswagen AG doe
tween wing mounting flange and sheet metal for mounting Vol
ks s no
t gu
wing underneath it. d by ara
ise n r tee
ho
♦ Installation position: aut or
ac
ss
“L” = -1- adapter is used on “right-hand” side of vehicle.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
vehicle.
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
The adapter on the “right” side of the vehicle is engaged in the
recess of the wing.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
op py
– Slide adapter - 10 - 222 A /3- and joint - T40091/3- onto support
t. C rig
gh ht
yri
bracket - 10-222 A- . p by
co Vo
by lksw
cted agen
– Secure support bracket - 10-222 A- to adapters - 10 - 222 A / Prote AG.
29- .
-A- = adapter - T40093/3-6A- (⇒ next figure)

– If present, pull off wires in front area of flange on both longi‐

tudinal members -arrow-. Do not disconnect pipe/hose sys‐
tem. agen
AG. Volkswagen AG d
o w es n
olks o
– Place adapter
ed
by
V
- T40093/3-6A- onto right longitudinal
t gu
ara member.
ris nte
– If anecessary,
ut
ho carefully unclip any pipes for air conditioning
eo
ra
system
ss in front area. Do not disconnect pipe/hose system
c ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
ce
e
nl
pt
du
System overview - refrigerant circuit .
an
itte
y li
erm
ab
– Bolt on spindle - T40093 /3- .
ility
ot p
– Connect spindle - T40093 /3- via square tube - T40091/1- to
wit
, is n
h re
engine support bracket - 10-222 A- and fasten the connection
hole
(⇒ previous fig.).
spec
es, in part or in w
– Then attach spindles to engine support eyes.
t to the co
rrectness of i
l purpos

insulation .
nf
ercia
orm
m
atio
m

o
n in
or c
thi

te
sd
iva
o
r
rp
cu
– Detach nut -3- from washer fluid reservoir -4- ⇒ Electrical

o
m
f
en
ng
system; Rep. gr. 92 ; Windscreen washer system; Removing

t.
yi Co
op
and installing washer fluid reservoir .
C py
t. rig
gh ht
yri by
This will allow for pushing washer fluid reservoir aside slightly at
cop Vo
by lksw
a later stage when removing the gearbox.
cted agen
Prote AG.
2) Disregard bolts -1 and 2-.

-arrows-.


– Detach connector -1- from oil level and oil temperature sender
- G266- , if fitted.
gr. 40 ; Drive shaft; Removing and installing drive shafts .
– If fitted, remove heat shield for right drive shaft -arrows- ⇒

moving and installing drive shaft
olks
wage heat shield . es n
o V t gu
by a
– Remove right driverisshafted from gearbox. ⇒ Running gear, rante
axles, steering; Rep.tho
gr. 40 ; Drive shaft; Removing and in‐ e or
au
stalling drive shaft
ss . ac
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
– Use tensioning strap - T10038- to secure drive shafts on sus‐

pension strut.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Remove clamp -2- for exhaust system from engine then raise
and tie front exhaust pipe ⇒ Rep. gr. 26 ; Exhaust pipes/
silencers; Assembly overview - silencer .
Disregard bolts -1-.
– Remove pendulum support. First remove bolt -1-, followed by

bolts -2- and -3-.
– Remove all but one »easily accessible« connecting bolt be‐
tween engine and gearbox from underneath.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
ti
engine/gearbox »only« on gearbox side as far as dimension on in
r
te o
thi
-a-.
s
iva
do
r
rp
Dimension -a- = about 80mm

um
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Remove radiator cowl with radiator fan -arrow- ⇒ Rep. gr. 19 ;

Radiator, radiator fan; Removing and installing radiator cowl .
– Place protective mat between radiator and engine.
– Secure bracket - T10346/1- to subframe as shown in illustra‐

tion using an M 8 x 25 bolt -left arrow-.
– Screw engine support - T50015- to bracket - T10346/1- and to
left threaded hole for heat shield on engine block
-right arrow-. To prevent damage to oil sump, insert a spacer
-A- e.g. M12 nut between engine support and engine. wage es n
olks ot V gu
by ara
– Force engine/gearbox as far forwards asopossible
ris
ed by turning nte
spindle of engine support - T50015- . Avoid
aut
h collisions of com‐ eo
ra
ponents. ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
Gearbox support - 3282- is aligned with adjustment plate -

is n
h re

ole,
spec
– Gearbox support - 3282- is inserted in engine and gearbox

t to the co
jack - VAS 6931- .

– Align arms of gearbox support according to holes in adjust‐
ment plate .
rrectne
– Screw support elements -A- into adjustment plate as illustra‐

s
ted. Deviating from this, pin - 3282/34- is used as rear right

s o
support element. This support element is located outside ad‐

cial p
f in
justment plate .
form
mer
• Support element -C- on adjustment plate is not used.

atio
om
n
c
– Position engine and gearbox jack - V.A.G 1383 A- with gear‐

i
or
n thi
e
box support - 3282- under gearbox.

t
sd
iva
o
pr
All gearboxes are supported as shown in the illustration.

um
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

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

– Remove »last« connecting bolt between engine and gearbox.
– Push gearbox off engine and lower it carefully, ensuring
»clearance« to other components.
Note

4.2.3 Removing gearbox, Golf 2017 ►, Golf

Estate 2017 ksw
►,
age vehicles
n AG with
. Volkswagen AG
doesdiesel en‐
not
l
gine,edall-wheel drive
Vo gu
by ara
is n tee
or
Brief description
au
th or
ac
ss
The gearbox is removed downwards together with the bevel box.
ce
e
nl
pt
»From above«
du
an
itte
y li
erm
The battery, air filter and starter are removed. The coolant hoses
ab
ility
must be clamped off. Support engine and gearbox before left

ot p
wit
subframe mounting is unbolted.

, is n
h re
hole
»From below«
spec
es, in part or in w
The -subframe- is removed together with -pendulum support- and

t to the co
-both suspension links-.

Both drive shafts are disconnected from gearbox and left installed
rrectness of i
in wheel bearing housings. They are only swivelled to one side

and left on vehicle.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


equipment required
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
op
♦ Support - 10-222A-
C py
ht. rig
rig ht
py by
♦ Shackle - 10 - 222 A /12- co Vo
by lksw
cted agen
Prote AG.
♦ Support - 10 - 222 A /31-
♦ Engine support, basic set - T40091-
♦ Engine support supplement set - T40093-


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 py
♦ Release lever - 80 - 200- t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Golf 2017 ➤ , Golf Sportsvan gen2015
AG. Vo➤
lks,wGolf
agen ASportsvan
G do 2018 ➤ , Golf Varia ...
swa es n
7-speed dual clutch gearbox
y Volk 0GC - Edition 07.2018 ot g
u
b ara
ed nte
ris
♦ Insert tool 18 mm -auT10179-
tho
or insert tool AF 18 - T10509- e or
ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
♦ Socket insert - T10061-
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Support bridge - T10323-

Removing:
height.
Note
So that the propshaft can be turned later in order to loosen it:
– Move selector lever to »N« position.

gr. 27 ; Battery; Removing and installing battery
agen
Atray
G. Vo.lkswagen AG d
o w es n
olks ot g
byV ua
ed ran
ris tee
tho or
au ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Remove bolts -arrows-

ss o
cial p
– Open screw-type clip -3- and remove charge air pipe -1- ⇒
inform
Rep. gr. 21 ; Charge air system; Assembly overview - charge

mer
air system .
atio
om
n
c
Disregard screw-type clip -2-.

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
lksw not
Note d byV
o gu
ara
ise nte
or eo
h
♦ On a warm engine, the cooling system
s aut is under high pressure. ra
c
s
ce
e
nl
pt
du
an
itte
y li
open carefully.
erm
ab
ility
ot p
wit
, is n
h re
escaping coolant.
hole
spec
es, in part or in w
t to the co
rrectness of i
– Seal connecting necks of gear oil cooler using suitable plugs
l purpos
from engine bung set - VAS 6122- .
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op py
. C rig
ht ht
rig
by turning in direction of starter and pull off connector. py by
co Vo
by lksw
cted agen
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Prote AG.
It is advisable to remove the »lower« bolt first.


– Remove fuel filter and lay to side. Do not open pipe/hose
n AG. Vosys‐
lkswagen AG
lkswage- fuel filter .
tem ⇒ Rep. gr. 20 ; Fuel filter; Assembly overview does
not
o V gu
d by ara
– If there are hoses and cable connections
or
ise in area of engine nte
support eye for support bracket - a10
u - 222 A- , remove these
th eo
ra
now. ss c
ce
le
un
pt
an
d
itte
y li
Required material:
erm
ab
ility
ot p
♦ Adapter - 10 - 222 A /3-
wit
is n
h re
ole,
spec
t to the co
♦ Adapter - 10 - 222 A /29- , qty. 2
♦ Square tube - T40091/1-
rrectne
♦ Connector - T40091/3-
♦ Spindle - T40093 /3-
ss o
cial p
f
♦ Check adapter - T40093/3-6- and modify as necessary
inform
⇒ page 88
mer
atio
m
♦ or adapter - T40093/3-6A-
o
n
c
i
or
n thi
te

sd
iva
o
r

p
cum
r
fo
wing underneath it.

en
ng
t.
yi Co
op
♦ Installation position: C py
t. rig
gh ht
yri by
“L” = -1- adapter is used on “right-hand” side of vehicle. cop Vo
by lksw
cted agen
Prote AG.
vehicle.


The adapter on the “right” side of the vehicle is engaged in the
recess of the wing.
– Slide adapter - 10 - 222 A /3- and joint - T40091/3- onto support

bracket - 10-222 A- .
29- .
n AG. Volkswagen AG
wage does
olks not
byV gu
ara
ed nte
ris
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i

l purpos
tem.
– Place adapter - T40093/3-6A- onto right longitudinal member.
nform
ercia
– If necessary, carefully unclip any pipes for air conditioning

m
at
om
system in front area. Do not disconnect pipe/hose system ⇒

ion
c
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;

in t
or
System overview - refrigerant circuit .

his
ate
do
priv
– Bolt on spindle - T40093 /3- .

um
for
en
ng
t.
– Connect spindle - T40093 /3- via square tube - T40091/1- to
yi Co
op
engine support bracket - 10-222 A- and fasten the connection
C py
t. rig
gh
(⇒ previous fig.).
ht
pyri by
Vo
co lksw
by
cted
agen
Prote AG.

Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; Re‐
moving and installing front wheel housing liner .

– Remove electrical wiring and retainer from front of sump

-arrows- (2 x M6 nuts).
– If fitted, pull connector -1- off oil level and oil temperature
sender - G266- .
– If fitted, pull connector off auxiliary pump for heating - V488- . Volkswag
en AG
⇒ Rep. gr. 19 ; Coolant pump, thermostat; Assemblyksoverview
wage
n AG does
not
- electric coolant pump . by
Vol gu
a d ran
ise
– Remove subframe ⇒ Running gear, axles, ho steering; Rep. gr.
r tee
ut or
40 ; Subframe; Removing and installing
ss
asubframe without ac
steering rack .
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
– Remove drive shaft heat shield, if present, from bevel box ⇒
spec
Running gear, axles, steering; Rep. gr. 40 ; Drive shafts; Re‐
es, in part or in w
t to the co
moving and installing drive shafts .
Right drive shaft heat shield is secured with 2 or 3 nuts -arrows-.
rrectness of i
– Detach left and right drive shafts from gearbox ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and
l purpos
installing drive shaft .
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
– Secure both drive shafts on suspension strut with tensioning

p
cum
or
belts - T10038- .
f
en
ng
t.
yi Co
The surface protection of the shafts must not be damaged. Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

lkswage es n
o ot g
byV ua
d ran
ir se
Golf 2017 ➤ , Golf Sportsvan
tho 2015 ➤ , Golf Sportsvan 2018 ➤ , GolfteeVaria or ...
au
ss 0GC - Edition 07.2018 ac
ce
le
un
pt
– Unscrew bolts -A- and -B-, and remove bevel box carrier -1-.
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
– Unscrew bolts -arrows- on bevel box, and remove heat shield

-1-.
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

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

Propshaft; Removing and installing propshaft .


AG. Volkswagen AG d
agen oes
o lksw not
– Secure support - T10323- with a bolt on inside d byrear threaded
V gu
ara
hole for subframe. orise nte
eo
h
aut ra
– A securing bolt from the subframe is suitable
ss for this. c
ce
e
nl
– Place cloth -A- on support and lay propshaft on that.
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Note
l purpos
♦ When removing and installing, do not damage seal in the
nform
ercia
propshaft flange -arrow-.

m
at
♦ Renew propshaft if damaged. ⇒ Rep. gr. 39 ; Propshaft; Re‐
om
io
moving and installing propshaft
n
c
in t
or
his
e
♦ All parts of propshaft which have been marked relative to each

at
do
riv
other must be reinstalled in the same positions.

p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
op Vo
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf
aut Sportsvan 2018 ➤ , Golf Varia ...
ho eo
ra
7-speed dual clutch gearbox 0GC - Edition
ss 07.2018 c
ce
e
nl
pt
du
an
itte
y li
erm
ab
-a-.
ility
ot p
wit
, is n
h re
hole
spec
– Remove all connecting bolts except one which is in an easily
es, in part or in w
accessible place between engine and gearbox.
t to the co
rrectness of i
l purpos
nform
ercia
– An engine/gearbox connecting bolt -arrow- is located next to

m
bevel box -A-.
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.

– Move engine and gearbox jack under gearbox and support
gearbox. Do not raise.
The gearbox is separated from the engine in this position.
– Remove last connecting bolt between engine and gearbox.
– Press gearbox off engine while »observing selector lever ca‐
ble«, and lower gearbox.
4.2.4 Removing gearbox, Golf 2017 ►, vehi‐

cles with petrol engine
Brief description
The gearbox is removed downwards separately.
»From above«
The battery, air filter and starter are removed. The engine and
gearbox must be supported before the left subframe mounting is
removed.
»From below«


equipment required
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
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rrectness of i
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Prote AG.
♦ Support - 10 - 222 A-
♦ Adapter - 10 - 222 A /29-
♦ Adapter - 10 - 222 A /18-
♦ Shackle - 10 - 222 A /12- qty. 2
♦ Pin - 3282/29-

♦ Adjustment plate - 3282/42 A-

♦ Insert tool, 18 mm - T10179-
AG. Volkswagen AG d
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♦ Release lever - 80 -
200-
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♦ Insert tool 18 mm -
an
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T10179- or insert tool
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AF 18 - T10509-
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♦ Socket insert -
mer
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T10061-
om
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Cop py
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♦ Square tube -
T40091/1- , qty. 2
♦ Connecting piece -
T40091/3- , qty. 2

♦ Spindle - T40093 /3-

from engine support
supplementary set -
T40093- , qty. 2
♦ Adapter -
T40093/3-6- : qty. 2
(check and modify as
necessary
⇒ page 112 )
♦ or adapter -
T40093/3-6A- : qty. 2
♦ Adjustment plate -
3282/61-
AG. Volkswagen AG d
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Check adapters -
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T40093/3-6- and modify

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– If necessary, cut off
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edges.
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– Protect adapter
m
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at
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- T40093/3-6- as -
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p
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bracket - 10-222 A- will Cop py
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members with adapters -
p by
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T40093/3-6A- . Prote
cted AG.
agen

Golf 2017 ➤ , Golf Sportsvan A2015
G. Volk➤
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Golf Sportsvan 2018 ➤ , Golf Varia ...
en AG
agen does
olksw 7-speed dual clutch gearbox not 0GC - Edition 07.2018
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• To prevent damage tho
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front section of the
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adapters -
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T40093/3-6A- with
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textile-reinforced ad‐
wit
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, is n
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tronic parts catalogue hole
spec
(ETKA chemical sub‐
es, in part or in w
stances) .
t to the co
Removing
– Raise vehicle. All 4
rrectness of i
supports of lifting
l purpos
platform must be at
same height.
nf
ercia
– Move selector lever
or
to position »P«.
m
m
atio
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– Remove engine cov‐

o
n in
or c
er panel ⇒ Rep. gr.
thi
te
10 ; Engine cover
sd
iva
o
r
panel; Removing and

rp
cu
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installing engine cov‐
f
en
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t.
yi
er panel .
Co
Cop py
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– Remove air filter
gh ht
pyri by
housing ⇒ Rep. gr.
o Vo
by c lksw
cted
24 ; Air filter; Remov‐
agen
Prote AG.
ing and installing air
filter housing
– Remove battery and
battery tray ⇒ Electri‐
cal system; Rep. gr.
27 ; Battery; Remov‐
ing and installing bat‐
tery
– Remove charge air pipe with charge air hose ⇒ Rep. gr. 21 ;
Charge air system; Assembly overview - charge air system .
escaping coolant.
Note

♦ Before pulling off the coolant hoses, cover the cap on the
coolant expansion tank with a cloth and open carefully.

AG. Volkswagen AG d
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olksw not
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Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan
thor 2018 ➤ , Golf Varia ... eo
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form
mer
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Cop py
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Vo
co lksw
by
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Prote AG.
– Remove all upper engine/gearbox connecting bolts.

AG. Volkswagen AG d
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by
Vol Golf 2017 ➤ , Golf Sportsvan
not
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d ara
rise 7-speed
nte dual clutch gearbox 0GC - Edition 07.2018
ho eo
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A bolt
ss is located in the starter motor hole -arrow-. This bolt can be
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support eye for support bracket - 10-222A- , remove these
ility
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Required material:
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♦ Adapter - 10 - 222 A /18-
♦ Shackle - 10 - 222 A /12- : qty 2 (required if spindles of support
rrectne
bracket cannot be hooked into lifting eyes of engine).
♦ Adapter - 10 - 222 A /29- , qty. 2
ss o
cial p
f
♦ Square section tube - T40091/1- , qty. 2
inform
mer
♦ Connecting piece - T40091/3- , qty. 2
atio
om
♦ Spindles - T40093 /3- qty. 2
n
c
i
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♦ Adapter - T40093/3-6- : qty. 2 (check and modify as necessary

t
sd
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⇒ page 88 )
i
o
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♦ or adapter - T40093/3-6A- : qty. 2

t.
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wing underneath it.
Prote AG.
♦ Installation position:
“L” = -1- adapter is to be inserted on “right” side of vehicle ( adapt‐
er is engaged in recess of wing).

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

T40091/3- onto support bracket - 10-222 A- .
29- .


tem.
– Place adapters - T40093/3-6A- onto both longitudinal mem‐
bers (illustration shows right longitudinal member).
– If necessary, carefully unclip any pipes for air conditioning
system in front area. Do not disconnect pipe/hose system ⇒
Heating, air conditioning; Rep. gr. 87 .; VRefrigerant circuit;
n AG olkswagen AG do
System overview - refrigerantkscircuit
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t to the co
– Position adapter - T40093/3-6A- on left longitudinal member
directly behind filler pipe for washer fluid reservoir.
• Each of the adapters - T40093/3-6A- locks with pin -A- behind
rrectne
the web of the longitudinal member -arrow-.
s
– Screw in spindles - T40093 /3- .
s o
cial p
f
– Connect spindles - T40093 /3- via square tubes - T40091/1-
to engine support bracket - 10-222 A- , and tighten (⇒ previous inform
mer
illustration).
atio
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Vehicles with front differential lock

– Pull connector -arrow- off transverse lock-up control unit -
J647- .
Continuation for all
– Remove subframe ⇒ Running gear, axles, steering; Rep. gr.
40 ; Subframe; Removing and installing subframe without
steering rack .

– Disconnect both drive shafts from gearbox ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Removing and installing drive
shaft .
– Secure drive shaft to suspension strut with tensioning strap -

T10038- .
AG. Volkswagen AG d
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t to the co
rrectness o
cial p
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mer
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117
AG.
4. Removing and installing gearbox

-a-.
Vehicles with front differential lock

– One engine/gearbox connecting bolt -arrow- is located next to
front differential lock.
AG. Volkswagen AG d
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ble«. Slightly tilt gearbox on the outside using spindle of gear‐

box support - 3282- .
nf
ercia
orm
m
atio
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– Now slightly turn gearbox and lower it. Be sure to guide flange
o
n in
c
-1- past intermediate plate -arrow- when lowering gearbox.

or
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4.2.5 Removing gearbox, Tiguan 2016 ►, ve‐

hicles with diesel engine, all-wheel drive
Brief description
»From above«

AG. Volkswagen AG d
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Golf 2017 ➤ , Golf Sportsvan 2015thor ➤ , Golf Sportsvan 2018 ➤ , Golf Varia ...e o
u ra
7-speed
ss a dual clutch gearbox 0GC - Edition 07.2018 c
ce
e
nl
pt
du
The battery is disconnected and, if located in engine compart‐
an
itte
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ment, removed. The air filter and starter are removed. The engine
erm
ab
and gearbox must be supported before the left subframe mount‐
ility
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ing is removed.
wit
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»From below«
hole
spec
-Subframe- is removed together with -pendulum support- and
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
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or c
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Cop py
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co lksw
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pt
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ility
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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te
sd
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pr
cum
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fo
en
ng
t.
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Cop py
t. rig
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by c lksw
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Prote AG.
♦ Insert tool 18 mm - T10179- or insert tool AF 18 - T10509-

AG. Volkswagen AG d
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V gu
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or eo
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es, in part or in w
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nf
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Cop py
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♦ Pin - 3282/29-
Removing
height.
– Move selector lever to position »P«.
– Remove engine cover panel ⇒ Rep. gr. 10 ; Engine coveren AG. Volkswagen AG
panel; Removing and installing engine cover panel . olkswag does
not
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– Remove air filter housing ⇒ Rep. gr. 24 ; Air ofilter;
ris
ed Removing nte
and installing air filter housing au
th eo
ra
ss c
ce
le
un
pt
an
d
itte
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– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
erm
ab
ility
27 ; Battery; Removing and installing battery
ot p
wit
is n
– Remove air intake pipe ⇒ Rep. gr. 21 ; Charge air system;
h re
ole,
Removing and installing air intake pipe .
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
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fo
en
ng
t.
yi Co
Cop py
ht. rig
– Unscrew bolts -2-, raise and tie cable support bracket -3- to‐ rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Note

open carefully.

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

3094- and remove.
AG. Volkswagen AG d
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olksw not
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– Disconnect connector -1- for mechatronic ised unit for dual clutch
b ara
nte
gearbox - J743- . To do this, turn rotary
ut
hor
locking mechanism eo
ra
anti-clockwise -arrow-. ss a c
ce
e
– Remove starter -A- ⇒ Electrical system; Rep. gr. 27 ; Starter;

nl
pt
du
an
itte
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erm
ab
It is advisable to remove the lower bolt first.
ility
ot p
wit
, is n
h re
hole
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es, in part or in w
t to the co
rrectness of i

l purpos
nf
ercia
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m
atio
om
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or c
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Prote AG.

removed using socket - T10061- . n AG. Volkswagen A ge G do
swa es
– Support engine and gearbox biny Vinstallation
olk position ⇒ Rep. gr.not gua
10 ; Assembly mountings;risSupporting engine in installation
ed ran
tee
position . utho or
a ac
ss
ce
e
nl
pt
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itte
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Rep. gr. 66 ; Noise insulation .
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
– Remove subframe ⇒ Rep. gr. 40 ; Subframe; Assembly over‐

view - subframe .
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
op
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– If fitted, remove drive shaft heat shield -1- from bevel box ⇒
moving and installing drive shaft .
Heat shield is secured with 2 or 3 nuts -arrows-.
shaft .

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– Secure drive shaft to suspensionkstrutgen AG
swa with tensioning strap
oes -
n AG d
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T10038- . by Vo gu
a d ran
ise
The surface protection of uthe
tho shafts must not be damaged.
r tee
or
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un
pt
Note
an
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itte
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The next figure shows the bevel box with a splined shaft instead
ility
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of a flange shaft.
wit
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– Unscrew bolts -A- and -B-, and remove bevel box carrier -1-.
rrectness o
cial p
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Cop py
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– Unscrew bolts -A- and -B- from bevel box and remove heat yri
gh by
ht
shield -1-. cop Vo
by lksw
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f
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pyri by
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– Place cloth -A- on support and lay propshaft on that. Prote
cted AG.
agen
Note


– 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.

-a-.
AG. Volkswagen A
– Remove all connecting boltsksw except one which is inesan
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not easily
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bevel box -A-.

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– Make sure to guide bevel box past intermediate plate when
lowering gearbox.
Note
Transporting gearbox ⇒ page 155 . . Volkswagen AG

gen AG does
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Secure gearbox to assembly stand b⇒y Vpage
olk 157 . not
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Install gearbox ⇒ page 150 . thoris eo
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nl
pt
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an
hicles with diesel engine, front-wheel
itte
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Brief description
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mains in the vehicle. t to the co

»from above«. Engine and gearbox must then be supported so
rrectness of i
that left and right assembly mounting can be detached.

l purpos
»From below«
Remove noise insulation beneath engine and cover in front left
nform
ercia
wheel housing.
m
at
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om
io
-steering rack-.
n
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Both drive shafts are pushed out of gearbox and left installed in
at
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wheel bearing housings. They are only swivelled to one side, but
p
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or
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Special tools and workshop equipment required Cop py
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♦ Pin - 3282/29- p by
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♦ Gearbox support - 3282- Prote AG.

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Cop py
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Prote AG.

♦ Pin - 3282/29-
AG. Volkswagen AG d
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Removing
spec
es, in part or in w
t to the co
height.
– Switch selector lever to »P« position.
rrectness of i
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nform
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m
a
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ion in
r
te o
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– Remove air intake pipe ⇒ Rep. gr. 21 ; Charge air system;
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Removing and installing air intake pipe .
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Prote AG.

Note

open carefully.

escaping coolant.


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– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Vol
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Removing and installing starter . d by ara
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It is advisable to remove the »lower« bolt first. s au ra
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– Support engine and gearbox in installation position ⇒ Rep. gr.
10 ; Assembly mountings; Supporting engine in installation
position .
insulation .

-arrows- (2 x M6 nuts). gen AG
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– Raise wiring in area ofd bsump
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– Remove subframe uth together with steering rack ⇒ Running
o eo
ra
gear, axles, steering;
ss
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Rep. gr. 40 ; Subframe; Removing and c
installing subframe with steering rack .
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es, in part or in w
t to the co
rrectness of i
axles, steering; Rep. gr. 40 ; Drive shaft: Removing and in‐

l purpos
stalling drive shafts .

nform
mercia
at
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c
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or
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ate
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Secure both drive shafts to suspension struts using tensioning
yi Co
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straps - T10038- . t. C rig
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yri by
cop Vo
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– Remove all but one »easily accessible« connecting bolt be‐
tween engine and gearbox.

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

gine ⇒ Rep. gr. 10 ; Assembly mountings; Assembly overview
- assembly mountings .
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– Remove securing bolts -arrows- of ut
assemblys amounting for ra
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– Press gearbox off engine, and (if not already done) remove
gearbox carrier while »observing selector lever cable«, and
lower gearbox.

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Brief description
hole
spec
es, in part or in w
t to the co
»From above«
The battery, air filter and starter are removed. The engine and
rrectness of i
gearbox must be supported before the left subframe mounting is
removed.
l purpos
»From below«
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tion in
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♦ Release lever h-o 80 - 200-
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r
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Cop py
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rig ht
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♦ Pin - 3282/29-
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Removing
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height.
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t.
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Cop py
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– Remove engine cover panel ⇒ Rep. gr. 10 ; Engine cover yri
gh by
ht
op Vo
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AG.

27 ; Battery; Removing and installing battery tray .
– Lever off selector lever cable -1- from gearbox selector

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using removal lever - 80 - 200- . lkswage does
not
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– Unscrew bolts -2-, raise and tie cable
ris support bracket -3- to‐
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Note
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open carefully.
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at
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c
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o
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escaping coolant.
a
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for
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– Clamp off coolant hoses using hose clamps to 25 mm Ø -
t. C rig
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– Seal connecting necks of gear oil cooler using suitable plugs Prote AG.

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

gearbox - J743- . To do this, turn rotary locking mechanism
anti-clockwise -arrow-. n AG. Volkswagen A ge G do
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– Remove starter ⇒ Electrical system; by
Rep.
Volk gr. 27 ; Starter; ot g
ua
Removing and installing starterris.ed ran
tee
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It is advisable to remove the lower
ss
au bolt first. ac
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t.
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– Support engine and gearbox in installation position ⇒ Rep. gr. yri
gh by
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10 ; Assembly mountings; Supporting engine in installation cop Vo
by lksw
position . cted agen
Prote AG.

Rep. gr. 66 ; Noise insulation .

– Remove subframe together with steering rack ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Subframe; Removing and
installing subframe with steering rack .

– Release electrical connector for auxiliary hydraulic pumpolks
wa1gfor
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gearbox oil - V475- -a- and pull off connector -b-.d by V ua
ran
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– Disconnect both drive shafts from gearbox u⇒th Running gear,
o
or
axles, steering; Rep. gr. 40 ; Removing and
ss
a
installing drive ac
shaft .
ce
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nl
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ab
ility
ot p
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T10038- .
rrectness of i
l purpos
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mercia
at
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ion
c
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or
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ate
do
priv
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for
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t.
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Cop py
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– Remove securing bolts -arrows- of assembly mounting for rig ht
py by
gearbox.
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Prote AG.

-a-.
Dimension -a- = about 90 mm


lowering gearbox.
Note
Be careful of all lines when lowering gearbox. n AG. Volkswagen AG do

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Transporting gearbox ⇒ page 155 . ir se
d b ua
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Secure gearbox to assembly stand ⇒ page 157au .
t or
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hicles with 2.0 l petrol engine, all-wheel
wit
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spec
Brief description
t to the co
»From above«
rrectne
The battery is disconnected and, if located in engine compart‐
s
ment, removed. The air filter and starter are removed. The engine
s o
and gearbox must be supported before the left subframe mount‐
cial p
f in
ing is removed.
form
mer
»From below«
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-Subframe- is removed together with -pendulum support- and i

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and left on vehicle. t. Cop py
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Special tools and workshop equipment required yri
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c
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t.
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Cop py
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pyri by
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Prote AG.

AG. Volkswagen AG d
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♦ Pin - 3282/29- agen oes
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Removing
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height.
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inform
mer

atio

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27 ; Battery; Removing and installing battery

t.
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Cop py
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rig ht
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AG. Volkswagen AG d
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Golf 2017 ➤ , Golf d bSportsvan 2015 ➤ , Golf Sportsvan
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au ra
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nl
pt
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spec
– Remove charge air pipe with charge air hose ⇒ Rep. gr. 21 ;
es, in part or in w
Charge air system; Assembly overview - charge air system .
t to the co
escaping coolant.
rrectness of i
l purpos
Note
nf
ercia
orm
m
atio
♦ Before pulling off the coolant hoses, cover the cap on the
om
coolant expansion tank with a cloth and open carefully.
n in
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– Seal connecting necks of gear oil cooler using suitable plugs t. C rig
gh ht
from engine bung set - VAS 6122- . yri
p by
co Vo
by lksw
cted agen
Prote AG.

– Remove all upper engine/gearbox connecting bolts.

– Support engine and gearbox in installation position ⇒ Rep. gr.
10 ; Assembly mountings; Supporting engine in installation
position .
sulation .
– Remove electrical wiring and retainer from. Vfront

olkswaof sump
gen AG
-arrows- (2 x M6 nuts). w agen AG does
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– Raise wiring in area of sump
ise
d b and secure it. ran
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– Remove subframe ⇒s auRunning
t
gear, axles, steering; Rep. gr. or
ac
40 ; Subframe; Removing and installing subframe without
s
ce
e
steering rack .
nl
pt
du
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ab
ility
ot p
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, is n
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hole
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– Release electrical connector for auxiliary hydraulic pump 1 for t to the co

gearbox oil - V475- -a- and pull off connector -b-. rrectness of i
l purpos
nform
mercia
at
om
ion
c
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or
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ate
do
priv
cum
for
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t.
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– If fitted, remove drive shaft heat shield -1- from bevel box ⇒ Cop py
.
ht rig
rig ht
py by
moving and installing drive shaft . co Vo
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cted agen
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Heat shield is secured with 2 or 3 nuts -arrows-.
AG.

shaft .


T10038- .
– Unscrew bolts -1- and -2-, and remove gearbox carrier from
bevel box.
– Unscrew bolts -A- and -B- from bevel box and remove heat
shield -1-.
AG. Volkswagen AG d
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mer
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Cop py
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rig ht
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Prote AG.


AG. Volkswagen AG d
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– Secure support - T10323- with a bolt on inside rear threaded tion in

r
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hole for subframe.

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– A securing bolt from the subframe is suitable for this.

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– Place cloth -A- on support and lay propshaft on that.
Co
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rig ht
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Note


olkswagen AG
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– Then use spindles of support bracket
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bevel box -A-.
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mer
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Cop py
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rig ht
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wage e
Gearbox support - 3282- isy Valigned
olks with adjustment plate - t gu
s no
3282/61- for removal ofisegearbox 0GC.
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– Move engine and
sa
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ole,
box support - 3282- .
spec
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lowering gearbox.
rrectne
Note
ss
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mer
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4.3 Installing gearbox
ng
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Install in the reverse order of removal, observing the following. opyri
gh by
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– Renew needle bearing in crankshaft ⇒ Rep. gr. 13 ; Crank‐ Prote
cted agen
shaft; Renewing needle bearing in crankshaft .
AG.
Note
If the needle bearing in the crankshaft is damaged, the gears

cannot be selected properly any more because the clutch is sup‐
ported on this bearing.
– Lightly grease journal and splines on gearbox.
– If there are no dowel sleeves -A- in the cylinder block for cen‐
tring the engine and gearbox, insert new dowel sleeves.
• Missing dowel sleeves result in misalignment of the axes of
engine and gearbox, leading to destruction of the needle bear‐
ing in the crankshaft.
– Check for proper seating of intermediate plate.
It must be possible to guide the engine and gearbox together by
hand until the engine flange and gearbox flange make contact all
around.
– If necessary, readjust gearbox support until engine and gear‐
box are »aligned with each other«.
– Turn crankshaft slightly if necessary.
Pay attention to selector lever cable when installing.
– Tighten gearbox to engine.

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

Specified torque: ⇒ page 153
– If removed beforehand, install radiator cowl with radiator fan

-arrow- ⇒ Rep. gr. 19 ; Radiator, radiator fan; Removing and
installing radiator cowl .
lkswage es n
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ed ran
– Reinstall nut -3- on washer fluid reservoir -4-. Specified
thoris
torque: tee
⇒ Electrical system; Rep. gr. 92 ; Windscreen washer
s au system; or
ac
Removing and installing washer fluid reservoir . s
ce
e
nl
pt
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erm
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ility
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t to the co
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ercia
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– Install pendulum support with new bolts. Specified torque: ⇒

t
sd
iva
Rep. gr. 10 ; Assembly mountings; Assembly overview - as‐

o
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rp
cu
sembly mountings .
o
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en
ng
t.
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– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Re‐ Cop py
moving and installing starter .
t. rig
gh ht
pyri by
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co
– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.
by lksw
cted agen
Prote
40 ; Drive shaft; Removing and installing drive shaft .
AG.

– If fitted, install heat shield for right drive shaft -arrows- ⇒ Run‐
ning gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing
and installing drive shaft heat shield .
lkswage es n
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ab
– Carefully remove strainer -1- of oil cooler with a screwdriver
ility
ot p
and check for contamination.
wit
, is n
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– Clean strainer if necessary and clip back in place
hole
spec
– Fit coolant hoses on gear oil cooler.
es, in part or in w
t to the co
– Install wire retainer on sump.
– Fit all electrical connectors on gearbox.
rrectness of i
l purpos
– Install battery tray and battery ⇒ Electrical system; Rep. gr.

27 ; Battery; Removing and installing battery .
nform
ercia

m
at
om
ion
c
in t
r
– Check coolant level ⇒ Rep. gr. 19 ; Cooling system, coolant;

o
his
te
Draining and filling coolant .

a
do
priv
cum
or
– Install lower part of front left wheel housing liner ⇒ General

f
en
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t.
yi Co
op
moving and installing front wheel housing liner . C py
t. rig
gh ht
yri by
– Install noise insulation ⇒ General body repairs, exterior; Rep. cop Vo
by lksw
gr. 66 ; Noise insulation; Removing and installing noise insu‐ cted agen
Prote AG.
lation .
Specified torques: ⇒ page 70

5 Assembly mountings
⇒ “5.1 Assembly overview - assembly mountings”, page 153
5.1 Assembly overview - assembly mountings
1 - Engine support
❑ ⇒ Rep. gr. 10 ; Assem‐ AG. Volkswagen AG d
bly mountings; Assem‐ agen oes
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V
bly overview - assembly ed by gu
ara
mountings horis nte
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2 - Engine mounting ss c
ce
le
❑ ⇒ Rep. gr. 10 ; Assem‐ un
pt
an
d
bly mountings; Assem‐
itte
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bly overview - assembly
erm
ab
ility
mountings
ot p
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3, 4, 5 - Bolt
h re
ole,
spec
❑ Specified torque ⇒ Rep.
gr. 10 ; Assembly
t to the co
mountings; Assembly
overview - assembly
mountings
rrectne
6 - Bracket
s
❑ Version
s o
cial p
f
7, 8, 9 - Bolt
inform
mer
atio
gr. 10 ; Assembly
om
n
mountings; Assembly
c
i
or
n
overview - assembly
thi
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mountings
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10 - Pendulum support
en
ng
t.
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op
11 - Bolt C py
t. rig
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❑ For pendulum support p by
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by c
to subframe
lksw
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Prote AG.
gr. 10 ; Assembly
mountings; Assembly
overview - assembly
5. Assembly mountings 153

mountings
12 - Bolt
❑ For pendulum support to gearbox
❑ Gearbox with threaded insert ⇒ page 154
❑ Specified torque ⇒ Rep. gr. 10 ; Assembly mountings; Assembly overview - assembly mountings
13 - Bolt
❑ For pendulum support to gearbox
❑ Gearbox with threaded insert ⇒ page 154
14 - Bolt
❑ For gearbox mounting to gearbox
❑ Qty. 3
❑ 60 Nm +90°
15 - Bolt
16 - Gearbox mounting
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Gearbox with threaded insert (e.g. “Heli-Coil”) forris securing pen‐
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♦ There are threaded inserts, e.g. “Heli-Coil” in the bolting holes

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for the pendulum support.

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♦ Distinguishing feature: shoulder along beginning of thread h re

hole
spec
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es, in part or in w
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♦ Note appropriate securing bolts and specified torque ⇒ Rep.

gr. 10 ; Assembly mountings; Assembly overview - assembly
mountings .
rrectness of i
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6 Transporting gearbox ss
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⇒ “6.1 Transporting gearbox”, page 155
pt
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⇒ “6.2 Transporting front differential lock”, page 156
erm
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6.1 Transporting gearbox
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♦ Gearbox mounting support - 3336-
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c
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t.
♦ Workshop hoist - VAS 6100-
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Transporting gearbox
– Bolt gearbox lifting tackle - 3336- to gearbox. When doing this,
lock in housing recess -arrow-.
6. Transporting gearbox 155

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• Number of visible holes (without bevel box) = 5. rised ara
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– With gearbox lifting tackle - 3336- attached, take up weight of
un
pt
gearbox using workshop hoist - VAS 6100- .
an
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6.2 Transporting front differential lock
rrectne
• Protect connectors on front differential lock from being dam‐
aged.
s
– Prepare front differential lock for transport as follows so that
s o
cial p
f
no oil can escape:
inform
mer
• Pump for front differential lock - V181- -arrows- is in one of
atio
illustrated positions during transport.
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7 Securing to engine and gearbox sup‐
erm
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ility
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port
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⇒ “7.1 Installing gearbox to engine and gearbox support”,
spec
page 157
es, in part or in w
t to the co
⇒ “7.2 Securing front differential lock to engine and gearbox sup‐
port”, page 158
rrectness of i
7.1 Installing gearbox to engine and gear‐
l purpos
box support
nf
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orm
♦ Support plate - VW 309-
m
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om
♦ or support plate - VW 309 A-
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♦ Gearbox support - VW 353-
♦ Engine and gearbox support - VAS 6095A-
7. Securing to engine and gearbox support 157

Secure gearbox on engine and gearbox support

– Secure gearbox on gearbox support - VW 353- and insert in
engine and gearbox support - VAS 6095- with retaining plate
- VW 309- .
Tip:
Risk of oil escaping when gearbox is turned.
♦ If the filled gearbox on the engine and gearbox support is
turned with the breather downwards, the breather on the gear‐
box housing must be sealed.
7.2 Securing front differential lock to engine

and gearbox support
♦ Support clamp - VW 313-
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♦ Gearbox support - T10108-
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spec
t to the co
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cial p
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mer
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tee
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– Set bevel box
ss or front differential lock onto hole number -4-
-arrow- in gearbox support - T10108- .
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le
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A - Place nuts M12 x 10 (qty. 4) between bevel box and gearbox
y li
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support .
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– Then, align bevel box or front differential lock with remaining
, is n
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3 holes, and secure it.
hole
spec
es, in part or in w
t to the co
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nform
mercia
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tion in
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7. Securing to engine and gearbox support 159

8 Gear oil circuit

⇒ “8.1 Assembly overview - gear oil circuit”, page 160
⇒ “8.2 Removing and installing gear oil cooler”, page 160
⇒ “8.3 Removing and installing gear oil filter”, page 163
⇒ “8.4 Removing and installing motor for auxiliary hydraulic pump
1 for gearbox oil V475 ”, page 164
8.1 Assembly overview - gear oil circuit
1 - Bleeder cap
2 - O-ring
❑ Renew
3 - Bolt
❑ 20 Nm
4 - Gear oil cooler
⇒ page 160
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❑ Removing and installing rised b ara
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⇒ page 70 ut
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6 - Bolt s
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❑ 8 Nm + 45°
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❑ Renew
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7 - Motor for auxiliary hydraulic
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pump 1 for gearbox oil - V475-
h re
hole
spec
⇒ page 164
es, in part or in w
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8 - Seal
❑ Renew
9 - Gear oil filter rrectness of i
l purpos
❑ Information about oil

and filter change
⇒ page 5
nform
ercia

m
at
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⇒ page 163
ion
c
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10 - O-ring
his
ate
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❑ Renew
p
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❑ Lubricate with gear oil

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11 - Filter housing C py
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12 - Heat insulation Prote AG.
8.2 Removing and installing gear oil cooler


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mer
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Removing
t
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– Move selector lever to position “P”.

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– Remove air filter housing ⇒ Rep. gr. 23 ; Air filter; Removing Cop py
t. rig
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co
– If necessary, remove battery and battery tray ⇒ Electrical sys‐
by lksw
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tem; Rep. gr. 27 ; Battery; Removing and installing battery
AG.
tray .
Note

open carefully.

escaping coolant.
8. Gear oil circuit 161

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– Clamp offs coolant hoses to gear oil cooler with hose clamps
ce
e
-3094- and remove. Loosen hose clips -arrows- to do this.
nl
pt
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– Seal open lines and unions with suitable plugs -1- from engine
erm
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bung set - VAS 6122- .
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Caution
hole
spec
es, in part or in w
No coolant must be allowed to drip into gearbox!
t to the co
rrectness of i
– Cover gearbox with cloths to catch any escaping coolant.
l purpos
– Unscrew bolts -arrows- and remove gear oil cooler -A-.
nform
mercia
at
om
ion
c
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or
his
ate
do
priv
cum
for
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Installing
♦ Renew O-rings -arrows- after each removal.
♦ Coat O-rings with gear oil to prevent pinching of rings during
assembly.
♦ If sealing surface on gear oil cooler is damaged, it must be
renewed.
– Carefully remove strainer -1- of oil cooler with a screwdriver

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

– Carefully bring gear oil cooler -A- into position. When doing
this, observe sealing surface and O-rings.
– Tighten bolts -arrows- in stages and in diagonal sequence.
– If removed, install battery and battery tray ⇒ Electrical system;
Rep. gr. 27 ; Battery; Assembly overview - battery .
– Check oil level and top up ⇒ page 168 .
– Check coolant level ⇒ Rep. gr. 19 ; Cooling system, coolant;
Draining and filling coolant .
gr. 66 ; Noise insulation; Assembly overview - noise insula‐
tion .
Specified torques
♦ Gear oil cooler to gearbox
8.3 Removing and installing gear oil filter

• There is normally no need to remove the gear oil filter.
• Gear oil filter change “yes or no”: ⇒ page 5 .
♦ Used oil collector and extractor - VAS 6622A-
AG. Volkswagen AG d
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Removing
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t to the co
– Remove noise insulation -1- ⇒ General body repairs, exterior;

insulation .
rrectness of i

l purpos
– Remove battery and battery tray -1- -arrows- ⇒ Electrical sys‐

nf
ercia
tem; Rep. gr. 27 ; Battery; Removing and installing battery .

orm
m
– Place used oil collection and extraction unit - VAS 6622A- un‐
atio
m
der gearbox.
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TIP:
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♦ A residual amount of gear oil remains in the oil filter. It runs out
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when filter housing is unscrewed.

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♦ Before unscrewing the filter housing, cover the area around
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the gear oil filter with a sufficient number of cloths.
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♦ Thoroughly clean oily areas on gearbox.
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– Unscrew filter housing -2- and remove filter element.

Renew missing or damaged heat insulation -1-.
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Install in reverse order of removal, observing thebfollowing:
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• Renew O-ring after removal. tho tee
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– Insert filter element -1- with intake collar -arrow- into gearbox. ss
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– Tighten filter housing.
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itte
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ab
– Install battery and battery tray ⇒ Electrical system; Rep. gr.
ility
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27 ; Battery; Exploded view - battery .
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hole
spec
es, in part or in w
t to the co
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tion .
l purpos
Specified torques
♦ Filter housing to gearbox
nf
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orm
m
atio
♦ Selector cable support bracket to gearbox
om
n in
⇒ “3.1 Assembly overview - selector mechanism”, page 46
or c
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8.4 Removing and installing motor for auxil‐

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en
iary hydraulic pump 1 for gearbox oil -

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V475-
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♦ Puller - T10530-
Removing


Vehicles with all-wheel drive:
– Remove bevel box ⇒ page 35 .
Vehicles with front differential lock:
– Remove front differential lock ⇒ page 174 .
– Remove bolts -arrows- (Shown on removed gearbox)
AG. Volkswagen AG d
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– Insert puller - T10530- in hole.
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– Turn knurled nut -2- clockwise until puller is fixed in position.
hole
spec
es, in part or in w
– Using puller - T10530- , carefully pull out pump motor to one

t to the co
side horizontally.
Installing
rrectness of i
– Renew seal
l purpos
– Push pump motor evenly into housing by hand.

– Tighten pump motor.
nform
ercia
Vehicles with all-wheel drive:

m
a
com
tion in

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Vehicles with front differential lock:

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– Install front differential lock ⇒ page 178 .

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Continuation for all: Cop py
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– Top up gear oil ⇒ page 171 , and check gear oil level p by
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⇒ page 168 .
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Specified torques
♦ ⇒ “8.1 Assembly overview - gear oil circuit”, page 160

9 Gear oil
⇒ “9.1 Overview of oil drain and inspection plugs”, page 166
⇒ “9.2 Tools for gear oil change”, page 166
⇒ “9.3 Checking gear oil level”, page 168
⇒ “9.4 Draining and filling gear oil”, page 171
9.1 Overview of oil drain and inspection plugs
1 - Overflow pipe
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2 - Seal ised b ara
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❑ Renew aut
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3 - Drain plug
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❑ For gear oil
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❑ 45 Nm
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4 - Drain plug for mechatronic
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unit
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❑ 10 Nm + 45°
es, in part or in w
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9.2 Tools for gear oil change


♦ Oil filling adapter - VAS 6262 A- with adapter - VAS 6262/1-
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♦ If necessary: adapter - VAS 6262/6- or adapter - VAS 6262/7-
pe
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nform
mercia
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com
tio
♦ Genuine 1 litre oil bottle, dual clutch gearbox oil; part number
n in
r
te o
⇒ Electronic Parts Catalogue

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♦ Vehicle diagnostic tester

♦ Safety glasses
♦ Acid-resistant protective gloves
9. Gear oil 167

Measure length of breather pipe attached to adapter for filling oil

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

pipe cutter -6056/2- .
– Clean adapter for filling oil - VAS 6262 A- .
AG. Volkswagen AG d
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9.3 Checking gear oil level

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♦ ⇒ “9.2 Tools for gear oil change”, page 166

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spec
Test conditions
t to the co
• Gearbox not in emergency running mode.

• Vehicle is placed on a four-pillar lifting platform or above an
rrectne
assembly pit to ensure it is in total horizontal position.

s
• Selector lever in position “P”.

s o
cial p
f i
• The parking brake button has been pulled to activate the elec‐
nform
tromechanical parking brake.

mer
atio
m
• The extraction hoses of a switched-on exhaust extraction sys‐

o
n
c
tem are connected.

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sd
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• Engine running at idling speed.

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• Air conditioning system and heater switched off.

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

– Select Dual clutch gearbox .

– Select Check oil level .
• Specification at start of test: not higher than 30°C, otherwise
allow the gearbox to cool down. agen
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– Remove noise insulation u⇒th General body repairs, exterior;
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Rep. gr. 66 ; Noise insulation;
ss
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Removing and installing noise c
insulation .
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Caution
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Risk of injury to eyes and hands from escaping oil.
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• Wear protective goggles.
spec
es, in part or in w
t to the co
• Wear acid-resistant gloves
rrectness of i
– Place used oil collection and extraction unit - VAS 6622A- be‐
low gearbox.
l purpos
• Engine is running at idling speed with selector lever in “P”.
nf
ercia
– Unscrew inspection plug -arrow-.
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9. Gear oil 169

• The accumulated gear oil flows out of the overflow pipe

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

The correct oil level is below the level of the overflow pipe.
For this reason, the overflow pipe must be unscrewed 2 turns
to enable the oil level to be checked and adjusted correctly.
AG. Volkswagen AG d
– Loosen overflow pipe 2 turns. agen oes
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• If some gear oil still escapes at a gear oil temperature ris of be‐
ed
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tween 35 and 45°C (caused by the increasing temperature),
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the gear oil level is OK. ss c
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• Irrespective of the gear oil level a small gush of oil escapes
pt
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from the overflow pipe every 30 seconds due to the cooling oil
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pulses for supplying the multi-clutch. This is not relevant for
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determining the gear oil level.
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• Do not re-use gear oil which has escaped.
hole
spec
– If the gear oil level is OK, tighten the overflow pipe and com‐
es, in part or in w
plete the work sequence ⇒ page 171 .
t to the co
Fill with gear oil
rrectness of i
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Caution
Gearbox damage from overfilling.
nform
ercia
The correct oil level is below the level of the overflow pipe.
m
at
om
ion
For this reason, the overflow pipe must be unscrewed 2 turns
c
in t
or
to enable the oil level to be checked and adjusted correctly.

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ate
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• The overflow pipe must be unscrewed by 2 turns.

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Cop py
– If no gear oil escapes on the overflow pipe at a gear oil tem‐ ht. rig
rig ht
perature of between 35 and 45°C, fill gear oil as follows.
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– Shake bottle before opening.
Prote AG.
– Screw dual clutch gearbox oil bottle onto adapter for oil filling
- VAS 6262 A- .
• If the thread of the bottle does not fit onto the oil filling adapter
- VAS 6262 A- , use adapter - VAS 6262/6- .

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– Screw adapter for oil filling - VAS 6262 A- into inspection plug
nl
pt
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opening hand-tight.
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– Hold bottle with adapter for oil filling - VAS 6262 A- as high as
ility
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possible over the dual clutch gearbox, and allow the gear oil
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to flow into the dual clutch gearbox.
h re
hole
spec
– To check, if the dual clutch gearbox has been filled sufficiently,
es, in part or in w
disconnect the quick-release coupling on adapter for oil filling
t to the co
- VAS 6262 A- at regular intervals, and seal the hose with your
finger or a clean plug.
rrectness of i
• The accumulated gear oil flows out of the overflow pipe
-arrow 2-.
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• Irrespective of the gear oil level there is always a slight amount

of gear oil which escapes.
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• Irrespective of the gear oil level a small gush of oil escapes
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determining the gear oil level.
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• Check the gear oil temperature on the vehicle diagnostic test‐ cted agen
Prote AG.
er , while filling gear oil. If 45°C are exceeded, stop filling gear
oil, and allow the gearbox to cool down.
– If the gear oil level is OK, perform the required measures for
completing the work sequence ⇒ page 171 .
Concluding measures
• Renew seal -arrow- for inspection plug.
– Unscrew adapter for oil filling - VAS 6262 A- from gearbox.
– Tighten overflow pipe.
– Tighten inspection plug -arrow-.

– Switch off ignition and separate diagnosis connections.
Specified torques
♦ ⇒ “9.1 Overview of oil drain and inspection plugs”, page 166
♦ Assembly overview - noise insulation ⇒ General body repairs,
exterior; Rep. gr. 66 ; Noise insulation; Assembly overview -
noise insulation .
9.4 Draining and filling gear oil

9. Gear oil 171

♦ ⇒ “9.2 Tools for gear oil change”, page 166

Test conditions
• Gearbox not in emergency running mode.
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• Wear protective goggles.
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– Unscrew inspection plug -arrow-.

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– Remove oil drain plug -arrow- from mechatronic unit.

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

Fill with gear oil

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

– Screw dual clutch gearbox oil bottle onto adapter for oil filling
- VAS 6262 A- .
• Use adapter - VAS 6262/6- if necessary.
– Screw adapter for oil filling - VAS 6262 A- into inspection plug
opening hand-tight. en AG. V
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– Hold bottle with adapter for by oil filling - VAS 6262 A- as high gas
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to flow into the dual
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– Start engine and allow it to run at idling speed.
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itte
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– Switch selector lever to “P” position.

h re
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– Do NOT switch off engine.

es, in part or in w
t to the co
– Then, check oil level and top up as necessary ⇒ page 168 .

Specified torques
rrectness of i
♦ ⇒ “9.1 Overview of oil drain and inspection plugs”, page 166

l purpos
♦ Assembly overview - noise insulation ⇒ General body repairs,

exterior; Rep. gr. 66 ; Noise insulation; Assembly overview -
nform
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noise insulation .
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9. Gear oil 173

10 Front differential lock

⇒ “10.1 Assembly overview - front differential lock”, page 174
⇒ “10.2 Removing front differential lock”, page 174
⇒ “10.3 Installing front differential lock”, page 178
⇒ “10.4 Removing and installing differential lock control unit J647
”, page 180
10.1 Assembly overview - front differential lock
1 - Front differential lock

2 - Countersunk bolt
❑ 30 Nm
3 - Heat shield
❑ For drive shaft.
4 - Nut
❑ Qty. 2 or 3
gr. 40 ; Drive shaft; As‐
sembly overview - drive
shaft .
5 - Bolt
❑ Qty. 4
❑ 40 Nm + 90°
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10.2 Removing front differential lock

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174
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Rep. gr.34 - Controls, housing Prote AG.
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♦ Bracket - T10533/2-
♦ Bolt - T10533/4-
Removing:
height.
10. Front differential lock 175

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right drive shaft bolt -arrow-.
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sulation .
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– If fitted, remove heat shield -1- for drive shaft -arrows- ⇒ Run‐
r
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ning gear, axles, steering; Rep. gr. 40 ; Drive shaft .
thi
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Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .
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Caution
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Risk of damage to flexible joint. Prote AG.
♦ Observe ⇒ Rep. gr. 26 ; Emission control; Assembly

overview - emission control .
– Remove front exhaust pipe from engine and tie it up ⇒ Rep.

gr. 26 ; Exhaust pipes/silencers; Assembly overview - silenc‐
er .
– Pull connector -arrow- off transverse lock-up control unit -

J647- .
– Release and pull off electrical connector -arrow- on oil level

and oil temperature sender - G266- .

– Unscrew pendulum support bolts -1- from gearbox.

– Push pendulum support to one side.
– Bolt bracket - T10533/2- -A- to engine support - T50015- -B-.

To do this, use an M8 x 30 bolt -1-.
– Bolt bracket -A- to gearbox using bolt - T10533/4- -C-.
– Bolt engine support -B- to subframe using an M8 bolt.
– Tighten bolts by hand.
– Push engine with engine support - T50015- as far forwards as
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ed
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ara
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and radiator.
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pt
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– Unscrew securing bolt for right flange shaft using socket . To

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do this, screw 2 bolts into flange and counterhold flange shaft

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with a lever.
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Renew countersunk bolt after removal.

h re
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spec
es, in part or in w
t to the co
rrectness of i
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nform
ercia
– Unscrew upper securing bolts -arrows- for securing front dif‐

ferential lock to gearbox.
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Cop py
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rig ht
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Prote AG.

– Unscrew lower securing bolts -arrows- for securing front dif‐

ferential lock to gearbox.
– Have a second mechanic push engine/gearbox assembly to‐
wards front end slightly.
– Carefully press front differential lock off gearbox and remove
it.
• Protect connector -arrow- from being damaged.
AG. Volkswagen AG d
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10.3 Installing front differential lock

spec
es, in part or in w
t to the co
– Push front differential lock completely onto gearbox. When rrectness of i
doing this, guide flange shaft/front differential lock input shaft
splines centrally together with differential. Turn flange shaft if
l purpos
necessary.
– If splines are correctly positioned and shafts are centred, then
nform
ercia
the front differential lock will slide to stop against gearbox.

m
at
– All cable ties which were opened or cut during removal must
om
ion
be renewed at the same points.

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Do not use securing bolts to pull the front differential lock against C py
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the gearbox. Otherwise the front differential lock will cant and the
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bolt holes may break off.
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Prote AG.
– Screw in lower securing bolts -arrows- for front differential lock

and tighten them. Specified torque: ⇒ Item 5 (page 174)

– Screw in upper securing bolts -arrows- for front differential lock

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and tighten them. Specified torque: ⇒ Item 5 (page w gen AG
a174) does
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es, in part or in w
t to the co
– Secure flange shaft using new countersunk bolt. Specified tor‐
que: ⇒ Item 2 (page 174)
rrectness of i
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– Remove engine support - T50015A- . Cop py
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– Install new bolts -1- securing pendulum support to gearbox ⇒

Rep. gr. 10 ; Assembly mountings; Assembly overview - as‐
sembly mountings .

– Connect connector -arrow- to transverse lock-up control unit -

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rrectness of i
– If present, install heat shield -1- for drive shaft -arrows- ⇒
Running gear, axles, steering; Rep. gr. 40 ; Drive shaft .
l purpos
– Top up gear oil in front differential lock ⇒ page 189 .
nform
ercia
– Assemble exhaust system ⇒ Rep. gr. 26 ; Exhaust pipes/

silencers; Assembly overview - silencer .
m
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tion in
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10.4 Removing and installing differential lock
C py
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control unit - J647-
p by
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Prote AG.
Removing
– Switch off ignition.
Depending on equipment version, the axle differential lock control
unit - J647- is covered by the noise insulation on some vehicles.
– In this case, remove noise insulation ⇒ General body repairs,
exterior; Rep. gr. 66 ; Noise insulation; Assembly overview –
noise insulation .

– Pull off connectors -1- and -2-.

– Unscrew bolts -arrows-, and remove axle differential lock con‐
trol unit - J647- .
Installing
Install in reverse order but note following:
– Test operation ⇒ page 203 .
Specified torques
♦ Axle differential lock control unit - J647- to front differential lock
⇒ page 202
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35 – Gears, shafts
1 Currently, no repairs can be made to
gears and shafts
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182 Rep. gr.35 - Gears, shafts

39 – Final drive - differential

1 Gear oil
⇒ “1.1 Checking gear oil level”, page 183
⇒ “1.2 Draining and filling gear oil”, page 183 AG. Volkswagen AG d
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• The bevel box is bolted to side of the gearbox
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• Specifications for gear oil ⇒ Electronic Parts Catalogue
an
d
itte
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ot p
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• Renew bolt for oil filler hole after each removal.
is n
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ole,
spec
t to the co
rrectne
insulation .
ss
– If necessary, unscrew nuts -arrows-, and detach heat shield
o
cial p
f
for right drive shaft.
inform
mer
atio
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n
c
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t.
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Cop py
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rig ht
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co Vo
by lksw
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Prote AG.
– Unscrew oil filler plug -1-.

• Specification: gear oil level to lower edge of filler hole.
– If necessary, top up gear oil ⇒ page 183 .
– Install heat shield for drive shaft ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40 ; Drive shaft; Removing and installing heat
shield for drive shaft .
Specified torques
♦ Oil filler plug ⇒ Fig. ““Specified torques”“ , page 187
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Assembly overview - noise insulation .
1.2 Draining and filling gear oil

• The gear oil in the bevel box must only be drained in the event
of repairs. The oil is not intended to be changed on a regular
basis.
• Specifications for gear oil ⇒ Electronic Parts Catalogue
1. Gear oil 183

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♦ Adapter - VAS 6262/6-
ss , if necessary
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♦ Filling device for Haldex coupling 2 - VAS 6291 A-
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♦ Adapter for oil filling - VAS 6291/3-
184 Rep. gr.39 - Final drive - differential

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d part number ⇒ Electronic parts nte
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♦ Safety goggles
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Draining
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• Renew oil drain plug and bolt for oil filler hole after each re‐
atio
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moval.
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– Remove noise insulation ⇒ General body repairs, exterior; t. C rig
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Rep. gr. 66 ; Noise insulation; Removing and installing noise pyri by
Vo
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insulation .
lksw
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low gearbox.
– Unscrew oil drain plug -2-, and drain gear oil.
– Screw in new oil drain plug -2-.
Replenishing
– If necessary, unscrew nuts -1-, and detach heat shield for right
drive shaft.
– Route hose of charging device for Haldex coupling 2 - VAS
6291 A- through engine compartment.
1. Gear oil 185

– Unscrew oil filler plug -1-.
– Screw adapter for oil filling -VAS 6291/3- in to stop.

– Engage angled piece of filling device for Haldex coupling. V2ol-kswage
VAS 6291 A- with adapter for oil filling -VAS 6291/3-
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– Ensure that valve -arrow- is closed.
es, in part or in w
t to the co
– Screw oil reservoir -1- onto charging device for Haldex cou‐
pling 2 - VAS 6291 A- .
rrectness of i
• In the case of some oil bottles, the adapter -VAS 6262/6- must
be used as well.
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– Open valve -arrow-, and hold up oil container as shown in il‐

lustration.
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• The bevel box will now be filled.

• If bevel box has been properly filled, oil will emerge from
adapter for oil filling -VAS 6291/3- .
– If gear oil has emerged from adapter
agen
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– When no more au oil flows back, remove filling device for Haldexr ac
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– Screw in »old« oil drain plug and tighten slightly.
an
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– Start engine, engage gear, and allow gearbox to turn for ap‐
pe
ility
prox. 2 minutes.
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– Turn off engine and unscrew plug from oil filler hole.
hole
spec
– Check oil level, if necessary top up gear oil again to lower edge
es, in part or in w
of filler hole.
t to the co
– Tighten new oil filler plug.
rrectness of i
• Clean bevel box thoroughly to remove any remains of the
emerged oil.
l purpos
– Install heat shield for drive shaft ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40 ; Drive shaft; Removing and installing heat
nform
ercia
shield for drive shaft .

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Specified torques
n in
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1- Oil filler plug
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• Renew after removal

um
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• 15 Nm
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2- Oil drain plug p by
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cted
• Renew after removal
agen
Prote AG.
• 15 Nm
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐

tion; Assembly overview - noise insulation .
1. Gear oil 187

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2 Oil for front differential lock
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ility
⇒ “2.1 Checking oil level for front differential lock”, page 188
ot p
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⇒ “2.2 Draining and filling oil for front differential lock”,
h re
hole
page 189
spec
es, in part or in w
2.1 Checking oil level for front differential
t to the co
lock
rrectness of i
Oil for front differential lock is available as a replacement part ⇒
Electronic parts catalogue (ETKA) .
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♦ Temperature gauge - VAS 6519-
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Prote AG.
♦ Used oil collector and extractor - V.A.G 1782-
♦ Not illustrated: Torque wrench - V.A.G 1331-

♦ Hose (approx. 1.50 m long, external diameter 15 mm), com‐
mercially available
♦ Funnel, commercially available
Conditions for testing
• Oil temperature must be 20 to 40°C.
The oil temperature can be measured using temperature gauge
- VAS 6519- .
• Vehicle level.
• In order to perform the oil level check, the front differential lock
must be in installation position.

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Check oil level.
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– Unscrew oil filler plug -arrow-.
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Always renew oil filler plug after removing.
h re
hole
spec
• Oil level is correct when front axle differential lock is filled to
es, in part or in w
lower edge of filler hole.
t to the co
– Screw in new oil filler plug -arrow- and tighten it to specified
torque.
rrectness of i
– If the oil level is not correct, top up oil ⇒ page 189 .
l purpos
Specified torque
♦ Oil filler plug ⇒ page 202
nf
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2.2 Draining and filling oil for front differen‐

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♦ Used oil collector and extractor - V.A.G 1782-
♦ Funnel, flexible - VAS 6675-
2. Oil for front differential lock 189

♦ Hose (approx. 1.50 m long, external diameter 15 mm), com‐

mercially available
♦ Funnel, commercially available
• Observe safety data sheet.
• Vehicle level. AG. Volkswagen AG d
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• The differential lock on the frontby V axle is in the installation po‐ t gua
ol no
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Risk of injury
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hole
spec
– If fitted, remove noise insulation ⇒ General body repairs, ex‐
es, in part or in w
terior; Rep. gr. 66 ; Noise insulation; Assembly overview -
t to the co
noise insulation .
– Position used oil collection and extraction unit - V.A.G 1782-
rrectness of i
under final drive.
l purpos
– Use funnel, flexible - VAS 6675- to drain the oil.

– Fit the funnel is such a way that no oil gets onto the subframe.
nform
ercia
– Unscrew oil drain plug -arrow- of front differential lock.

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– Completely drain oil for front differential lock .

The illustration shows an example of how to use the funnel.
Note
If the oil is not going to be reused, observe the regulations for agen
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– Screw in new oil drain plug -arrow- (⇒ previous illustration),
utho eo
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and tighten it to specified torque. ss a c
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Specified torque
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♦ Oil drain plug ⇒ page 202
hole
spec
es, in part or in w
Replenishing oil for front differential lock
t to the co
– Renew oil filler plug after each removal.
• Vehicle level.
rrectness of i
l purpos
– Position used oil collection and extraction unit - V.A.G 1782-

under front differential lock.
nform
ercia
– Use a hose (approx. 1.50 m long, external diameter 15 mm),

commercially available and a funnel, commercially available
m
at
om
i
for filling oil.
on
c
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or
– Route hose -A- through engine compartment.
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ate
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Cop py
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– Clean area around oil filler plug -arrow- of front differential lock.
– Cover surrounding components.
– Unscrew oil filler plug -arrow-.
2. Oil for front differential lock 191

– Insert hose -A- into filler hole -arrow-.

• Do not allow hose to sag.
– Insert funnel into hose -A-.

– Top up oil until oil escapes between hose and filler hole.
– Remove hose . Excess oil may escape while doing so. agen
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• Oil level is correct when front differential lock is filled to lower d by V gu
ara
edge of filler hole. orise nte
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– Screw in new oil filler plug -arrow- and tighten it to specified
spec
torque.
es, in part or in w
t to the co
– Clean area around oil filler plug -arrow- of front differential lock.
If necessary, clean surrounding components.
rrectness of i
Specified torque
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♦ Oil filler plug ⇒ page 202
nform
mercia
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AG. Volkswagen AG d
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⇒ “3.1 Overview of fitting locations
ut
ho - seals”, page 193 eo
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⇒ “3.2 Renewing left seal”, page 193
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⇒ “3.3 Renewing right oil seal”, page 196
itte
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⇒ “5.5 Renewing seals for front differential lock”, page 205
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3.1 Overview of fitting locations - seals
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spec
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1 - Seal, right
t to the co
❑ Renewing ⇒ page 196
2 - Seal
rrectness of i
❑ For selector shaft
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3 - Left seal
orm
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3.2 Renewing left seal

3. Oil seals 193

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♦ Puller - T10055-
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♦ Drip tray for workshop hoist - VAS 6208-
♦ Electric drill, commercially available

Removing
gr. 40 ; Drive shafts; Removing and installing drive shafts .
Note
Only drill through sheet metal ring (about 3 mm), otherwise bear‐
ing located behind it might be damaged.

AG. Volkswagen
– Grease drill bit -3- so that metal
lksw
agchips
en adhere to Ait.G does n
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– Seal drive shaft aperture
ris
ed on transmission with a clean cloth ran
b a
tee
-2-. utho
or
sa ac
– Carefully drill a shole with a drill bit -3- (diameter 2 to 4 mm) into
ce
outer sheet metal ring -1- of oil seal. le
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es, in part or in w
t to the co
– Screw a self-tapping screw, approx. 4 mm in diameter, into
hole drilled in oil seal. Do not screw in sheet metal screw too
rrectness of i
far to avoid damaging bearing behind it.
l purpos
– Place drip tray for workshop hoist - VAS 6208- below gearbox.
– Pull out oil seal using puller - T10055- and adapter -
nform
ercia
T10055/2- .
m
a
com
ti
Make sure no metal chips get into gearbox and into opening for
on in
drive shaft. Vacuum out metal chips first if necessary.
r
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– Carefully remove cloths and make sure that no metal chips get
do
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into gearbox.
um
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– Carefully clean gearbox and opening for drive shaft.
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If only the sheet metal ring could be pulled out, carefully lever out
ht
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rest of seal with a screwdriver.
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Installing
doing this:
Before installing the seal, apply sealing grease for oil seal - G 052
128 A1- to sealing lips and cavity, and apply oil to outer circum‐
ference.
Installation position:
Open side of oil seal faces gearbox.
– Drive oil seal in to stop with thrust piece - T10457- . Do not

cant oil seal in the process.
3. Oil seals 195

– Lightly grease splines -arrow- on stub shaft with moly lubricant

- N 052 735 Y0- .
– Install left drive shaft ⇒ Running gear, axles, steering; Rep.
AG. Volkswagen AG d
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⇒ “3.3.1 Renewing right seal, vehicles with front-wheel
utho drive”, eo
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page 196 ss a c
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nl
⇒ “3.3.2 Renewing right oil seal - all-wheel drive vehicles”,
pt
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page 198
itte
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3.3.1 Renewing right seal, vehicles with front-
ility
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♦ Puller - T10055-
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♦ Used oil collector and extractor - VAS 6622A- Cop py
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♦ Not illustrated: thrust piece - T40372-

♦ Electric drill, commercially available
♦ Metal drill bit, 2 to 4 mm in diameter, commercially available
Removing

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Note
itte
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Only drill through sheet metal ring (about 3 mm), otherwise bear‐
ot
wit
ing located behind it might be damaged.
, is n
h re
hole
spec
– Grease drill bit -3- so that metal chips adhere to it.
es, in part or in w
t to the co
– Seal drive shaft aperture on gearbox with a clean cloth -2-.
– Using the 2 … 4 mm drill bit, carefully drill a hole into outer
rrectness of i
sheet metal ring -1- of oil seal.
l purpos
low gearbox.
nform
mercia
a
com
tion in
r
te o
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– Screw a self-tapping screw, approx. 4 mm in diameter, into
fo
en
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hole drilled into oil seal.

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t.
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Cop py
– Pull out seal using puller - T10055- and adapter - T10055/2- .
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– Carefully remove cloths. When doing this, make sure that no
by c lksw
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metal chips get into gearbox.
Prote AG.
– Carefully clean gearbox and opening for drive shaft.
Installing
– Apply gear oil to circumference and sealing lips of new oil seal.
• Installation position: open side of seal faces towards gearbox
– Fit seal by hand in a straight line, and push it in as far as pos‐
sible so that it is firmly seated in gearbox housing.
– Drive in oil seal as far as stop using thrust piece - T40372- ,

taking care not to cant oil seal.
3. Oil seals 197

3.3.2 Renewing right oil seal - all-wheel drive

vehicles
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♦ Extractor hook - T20143-
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hole
spec
es, in part or in w
t to the co
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♦ Sealing grease - G 052 128 A1-

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– Remove bevel box ⇒ page 35 . C py
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– Place used oil collection and extraction unit - VAS 6622A- be‐ cop Vo
by lksw
low gearbox. cted agen
Prote AG.

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7-speed
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dual clutch gearbox 0GC - Edition ran 07.2018
tee
tho
u or
a ac
– Lever out oil seal on dual clutch gearbox susing
s extractor tool
ce
e
- T20143/1- or - T20143/2- .
nl
pt
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es, in part or in w
t to the co
rrectness of i
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– Moisten new oil seal with gear oil along its outer circumfer‐
ence.
nform
ercia
– Fill space between sealing lip and dust lip -arrow- with sealing
m
at
grease - G 052 128 A1- .
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– Carefully drive in oil seal to stop using thrust piece - T10049- .

3. Oil seals 199

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⇒ “4.1 Removing and installing right flange shaft”,
ss page 200 c
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4.1 Removing and installing right flange
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⇒ “4.1.1 Removing and installing flange shaft - vehicles with all-
is n
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ole,
spec
4.1.1 Removing and installing flange shaft - urposes, in part or in wh
t to the co
vehicles with all-wheel drive
rrectne
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♦ Puller - T10037-
♦ Socket - T10107A-
Removing

– Unscrew nuts -arrows-, and remove heat shield for right drive
shaft.
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low gearbox.
h re
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spec
– Remove bolt for right flange shaft using socket - T10107 A- by
es, in part or in w
screwing 2 bolts into flange and counterholding flange shaft
t to the co
with an assembly lever.
rrectness of i
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nform
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ion
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– Pull out flange shaft -1- using puller - T10037- .
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-A- = M10 x 25 bolts
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Use puller - T10037- to remove the flange shaft to avoid damage
cop Vo
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to bearings of the flange shaft.
agen
Prote AG.
In the upper area of the bevel box, there is a hexagon bolt -B- with
an M 8 stud.
– To support the puller fit the thrust piece - T10135- onto this
hexagon bolt.
– Use spindle -C- to align puller parallel to flange.
– Pull out flange shaft.
Installing
– Carefully drive in flange shaft while turning it.
– Bolt on flange shaft.
– Check gear oil level ⇒ page 183 .
Specified torques
♦ Flange shaft bolt: 25 Nm
♦ Drive shaft; Assembly overview - drive shaft ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Drive shaft; Assembly overview
- drive shaft
4. Differential 201
5 Components of front differential lock

⇒ “5.1 Assembly overview - components of front differential lock”,
page 202
⇒ “5.2 Checking function”, page 203
⇒ “5.3 Removing and installing pump for front differential lock
V181 ”, page 203
⇒ “5.4 Removing and installing coupling for front differential lock”,
page 205
⇒ “5.5 Renewing seals for front differential lock”, page 205
⇒ “5.6 Renewing ball bearing for flange shaft”, page 212
5.1 Assembly overview - components of front differential lock
1 - Front differential lock

2 - Seal
❑ For flange shaft in front
differential lock
❑ Renew with front differ‐
ential lock removed
⇒ page 211
3 - Support washer
❑ Not a replacement part
4 - Seal
❑ Between front differen‐
tial lock and gearbox
❑ Renew with front differ‐ AG. Volkswagen AG d
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⇒ page 209 byV gu
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5 - Bolts aut
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❑ 9 Nm
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6 - Pump for front differential

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lock - V181-
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wit
⇒ page 203
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hole
7 - O-ring
spec
es, in part or in w
❑ For pump for front differ‐

t to the co
ential lock - V181-

❑ Moisten O-rings with oil
for front differential lock
rrectness of i
8 - Transverse lock-up control

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unit - J647-
nf
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⇒ page 180
rm
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9 - Bolts
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❑ 9 Nm
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10 - Ball bearing
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❑ For flange shaft in front differential lock

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❑ Renew with front differential lock removed ⇒ page 212 ht. Cop py
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202
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Prote AG.
Rep. gr.39 - Final drive - differential
11 - Retaining ring
❑ For ball bearing
12 - Seal
❑ For flange shaft
❑ Renew with front differential lock installed ⇒ page 205
13 - Flange shaft
❑ Removing and installing ⇒ page 208
14 - Retaining ring
❑ For flange shaft in front differential lock
❑ Renew after removal of flange shaft
AG. Volkswagen AG d
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15 - Bolt olksw not
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❑ With M8 stud rised
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❑ 40 Nm s aut ra
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16 - Bolt
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❑ With M8 stud
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❑ 40 Nm
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17 - Oil drain plug
is n
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ole,
spec
❑ With O-ring
t to the co
❑ Moisten O-ring with oil for front differential lock
❑ 15 Nm
rrectne
18 - Hydraulic fluid filler plug
ss o
❑ With O-ring
cial p
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❑ Moisten O-ring with oil for front differential lock
mer
❑ 15 Nm
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5.2 Checking function

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If individual parts such as the pump or control unit are renewed, cted agen
Prote AG.
a basic setting must be carried out. If the complete unit is renewed
(front differential lock), the basic setting is not required.
– After installing pump for front differential lock - V181- and axle
differential lock control unit - J647- , perform Basic set-
ting in Guided functions using ⇒ Vehicle diagnostic test‐
er .
5.3 Removing and installing pump for front

differential lock - V181-
5. Components of front differential lock 203

Removing
– Switch off ignition.
On some vehicles, pump for front differential lock - V181- is con‐
cealed by noise insulation.
– In this case, remove noise insulation ⇒ General body repairs,
exterior; Rep. gr. 66 ; Noise insulation; Assembly overview –
noise insulation .
– Pull off wiring harness -arrow- for pump for front differential
lock . gen AG
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– Unscrew bolts -1- of pump for front differential lock
db
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– Pull out pump for front differential lock -2-.utho eo
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Installing
Install in reverse order but note following: rrectness of i
– If necessary, renew O-rings -1- and -2- and lightly coat with oil
for front differential lock .
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– Push in pump for front differential lock -2- as far as stop. When
doing so, observe routing of wiring harness.
– Tighten bolts -1- to specified torque.
– Push electrical connector -arrow- for pump for front differential
lock onto axle differential lock control unit - J647- .
– Check level of oil for front differential lock and top up if nec‐
essary ⇒ page 188 .
– Test operation ⇒ page 203 .
Specified torque
Pump for front differential lock ⇒ page 202
5.4 Removing and installing coupling for

front differential lock
The coupling is located in the front differential lock.
The coupling is removed and installed together with front differ‐
ential lock ⇒ page 174
5.5 Renewing seals for front differential lock

⇒ “5.5.1 Renewing outer seal on right of front differential lock”,
page 205
⇒ “5.5.2 Renewing seal between front differential lock and gear‐
box on front differential lock”, page 209
⇒ “5.5.3 Renewing seal for right flange shaft in front differential
lock”, page 211
5.5.1 Renewing outer seal on right of front differential lock

AG. Volkswagen AG d
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equipment required agen
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Cop py
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Prote AG.

♦ Multi-purpose tool - VW 771 A-

♦ Hexagon key extension, 8 mm - 3247-
wage
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♦ Supplementary set for engine
ed and gearbox support - VW 540/1
by ara
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♦ Drip tray - V.A.G 1306-
ss c
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un
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♦ or drip tray for workshop hoist - VAS 6208-
an
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ot
♦ Sealing grease - G 052 128 A1-
wit
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Removing
hole
spec
es, in part or in w
The right drive shaft will be removed in a later step.
t to the co
– While vehicle is still standing on its wheels, loosen front right
flange bolt -arrow- by a maximum of 90°, otherwise the wheel
rrectness of i
bearing will be damaged. ⇒ Running gear, axles, steering;
l purpos
– If fitted, remove noise insulation ⇒ General body repairs, ex‐

terior; Rep. gr. 66 ; Noise insulation; Assembly overview -
nform
ercia
noise insulation .
m
a
– Drain oil from front differential lock ⇒ page 189 .
com
tion in
r
te o
thi
s
iva
– Remove drive shaft heat shield -arrows- ⇒ Running gear,
do
r
rp
c
axles, steering; Rep. gr. 40 ; Drive shaft .
um
fo
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ng
t.
yi
Co
op py
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Unscrew right flange shaft bolt -arrow- using socket . To do

this, screw 2 bolts into flange and counterhold flange shaft with
an assembly lever.

Supplement multi-purpose tool - VW 771- with supplementary set

for engine and gearbox support - VW 540/1 B- .
-a- = washer
– Bolt flange shaft to multi-purpose tool - VW 771- and pull out.
AG. Volkswagen AG d
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Note
hole
spec
es, in part or in w
♦ The flange shaft is secured with a retaining ring -arrow-.
t to the co
♦ Check if the retaining ring -arrow- is present.
rrectness of i
l purpos
nform
mercia
a
com
tion in
If necessary, remove the retaining ring from the area of the seal
r
te o
thi
-1- or of the ball bearing -2-.
s
iva
do
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rp
c
– Lever out flange shaft seal -1- using assembly lever.
um
fo
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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.
Installing
– Lightly oil outer circumference of new oil seal.
– Drive in new oil seal to stop, being careful not to cant oil seal.

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ss
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pt
– Fill space between sealing lip and dust lip -arrow- with sealing
du
an
itte
grease - G 052 128 A1- .
y li
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
nf
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Renew retaining ring -arrow-.
orm
m
– Push in flange shaft to stop by hand.
atio
om
n in
c
– Drive in flange shaft, being careful not to cant it.

or
thi
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sd
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– Tighten flange shaft with countersunk bolt.

iv
o
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rp
cu
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– Top up gear oil in front differential lock ⇒ page 189 .
f
en
ng
t.
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op
Install in reverse order of removal, observing the following: C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– If present, install drive shaft heat shield -arrows- ⇒ Running

gear, axles, steering; Rep. gr. 40 ; Drive shaft .
tion .
Specified torque
♦ Countersunk bolt for flange shaft ⇒ Item 2 (page 174)
5.5.2 Renewing seal between front differential

lock and gearbox on front differential
lock
♦ Removal tool - T20143-

AG. Volkswagen AG d
agen oes
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Removing
wit
, is n
h re
hole
spec
es, in part or in w
– Secure front differential lock on engine and gearbox support
t to the co
⇒ page 158 .
As opposed to the scenario shown in the illustration the flange
rrectness of i
shaft does not need to be removed.
l purpos
– Lever out seal.

• Do not damage the plastic container -A- and the support wash‐
nform
ercia
er -B-.
m
a
The support washer -B- is located right below the seal.
com
tion in
r
Installing
te o
thi
s
iva
do
• When installing the seal, make sure that support washer -B-
r
rp
cum
is inserted ⇒ page 202 .
fo
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t.
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op py
– Fill half of space between sealing lip and dust lip -arrow- with t. C rig
gh ht
sealing grease - G 052 128 A1- . yri
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Prote AG.
– Drive in new seal to stop, being careful not to cant seal.

– Check oil level for front differential lock ⇒ page 188 .

5.5.3 Renewing seal for right flange shaft in

front differential lock
♦ Multi-purpose tool - VW 771-
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♦ Extractor hook - VW 771/37-
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cial p
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mer
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t.
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Cop py
t. rig
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pyri by
Vo
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Prote AG.
Removing
– Secure front differential lock to engine and gearbox support
⇒ page 158 .
– Remove flange shaft ⇒ page 208 .

The seal is located in the front differential lock before the roller
bearing -A-.
Caution agen
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Do not damage the roller bearing -A- when removing theriseseal.
d
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Installation position of seal: ss au ra
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105 mm below upper edge/hollow shaft
un
pt
an
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erm
ab
ility
– Pull out seal using multi-purpose tool - VW 771- and extractor
ot p
wit
hook - VW 771/37- .
is n
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ole,
• Push extractor hook - VW 771/37- firmly into seal
spec
-direction of arrow-.
t to the co
Installing
rrectne
– Fill half of space between sealing lip and dust lip -arrow- with
sealing grease - G 052 128 A1- .
ss o
cial p
f inform
mer
atio
om
n
c
i
or
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sd
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Installation position of seal:
t. C rig
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• Open side -arrow- faces towards inside of front differential lock
c by lksw
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(towards front differential lock). Prote AG.
– Drive in new seal to stop, being careful not to cant seal.

– Install flange shaft ⇒ page 208 .
– Replenish oil for front differential lock ⇒ page 189 .
5.6 Renewing ball bearing for flange shaft


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♦ -1- internal puller, e.g. KUKKO 21-5 - VAS 251 611-
hole
spec
es, in part or in w
t to the co
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nform
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♦ Adapter from sliding hammer -Kukko 22-0-1-
r
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♦ Press tool - VW412-

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♦ Thrust piece - VW473-
♦ Thrust plate - VW401-

♦ Thrust plate - VW402-
Removing

– Secure front differential lock on engine and gearbox support

⇒ page 158 .
– Remove flange shaft ⇒ page 208 .
– Lever out flange shaft oil seal with assembly lever.
– Remove retaining ring in front of ball bearing ⇒ page 202 .
– Pull out ball bearing for flange shaft.
. Volkswagen AG
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A - Internal puller e.g. KUKKO
Vol
ksw21-5 - VAS 251 611- es not
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B - Adapter from sliding
or
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th or
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spec
Installing
t to the co
• The smaller end of thrust piece - VW473- points towards ball
bearing.
rrectne
• Fit press tool - VW473- centrally onto ball bearing.
• Do not damage the plastic container -A-.
ss o
– Press in ball bearing for flange shaft to stop.
cial p
f inform
– Secure ball bearing with new retaining ring.
mer
atio
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– Install seal for flange shaft ⇒ page 205 .

o
n
c
i
or
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– Install flange shaft ⇒ page 208 .

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Prote AG.

6 Components of bevel box

⇒ “2.2 Distinguishing between different types of bevel boxes”,
page 35 .
⇒ “6.1 Assembly overview - components of bevel box”,
page 215
⇒ “6.2 Renewing bevel box seals”, page 219
⇒ “6.3 Renewing output flange and redetermining thickness of
shim”, page 241
6.1 Assembly overview - components of

bevel box
⇒ “6.1.1 Assembly overview - components of bevel box, 0AV /
0FV ”, page 215
⇒ “6.1.2 Assembly overview - components of bevel box, 0CN ”,
page 217
6.1.1 Assembly overview - components of bevel box, “0AV / 0FV”

(Seals, flange shaft mount, output flange mount in bevel box)
1 - Seal
❑ Between bevel box and
bevel box
❑ Replacing with bevel
box removed
⇒ page 219
2 - Bevel box agen
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❑ Removing ⇒ page d by 35
V gu
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❑ Installing ⇒thopage 41
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3 - Oil drain plug
ss
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nl

pt
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❑ With captive seal

erm
ab
ility
❑ 15 Nm
ot p
wit
, is n

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hole
spec

es, in part or in w

t to the co
❑ 15 Nm
5 - Seal
rrectness of i

l purpos
❑ For right flange shaft

❑ Renewing with gearbox
nform
ercia
and bevel box installed

m
⇒ Rep. gr. 39 ; Oil

at
om
seals; Renewing right oil

on
c
in t
seal
or
his
ate
do
riv
6 - Breather pipe
p
cum
or
❑ To vent bevel box

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❑ Press in until stop is Cop py
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Prote AG.
6. Components of bevel box 215

7 - Cap
8 - Breather pipe
❑ Allocation ⇒ Electronic parts catalogue (ETKA)
10 Nm
9 - Bolt
❑ 5 Nm
10 - Shield
❑ Not fitted in all bevel boxes
❑ The outline may differ from that shown in the diagram.
11 - Right flange shaft
❑ Removing and installing ⇒ Rep. gr. 39 ; Oil seals; Renewing right oil seal
12 - Seal
❑ To renew, remove needle bearings (polygon bearings) ⇒ Rep. gr. 39 ; Components of bevel box
13 - Needle bearing (polygon bearing)
❑ Needle bearing (polygon bearing) is difficult to turn with flange shaft removed The fact it is difficult to
move does not mean that the bearing is defective. An acoustic test can only be performed with the
bearings installed.
n AG. Volkswagen AG
❑ Inspect for signs of damage to bearings, such as cracking wage in outer race, anddorenew
ot g if necessary.
lks es n
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❑ Renewing ⇒ Rep. gr. 39 ; Components of bevel ris
e box
d ran
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tho eo
14 - Locking ring ss
au ra
c
ce
le
un
pt
an
d
❑ For needle roller bearing (polygon bearing)

itte
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erm
ab
❑ Insert in circumferential groove in stub shaft
ility
ot p
wit
15 - Hexagon nut
is n
h re
ole,
spec

❑ Install using locking fluid - D 000 600- t to the co
rrectne
❑ 480 Nm
16 - Output flange
ss o

cial p
f inform
17 - Cover
mer
atio
❑ Not fitted in all bevel boxes

om
n
c
❑ Renew if damaged
i
or
n thi
te

sd
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pr
❑ Engage with output flange

um
r
fo
en
ng
t.
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18 - Shim
Co
Cop py
. rig
❑ Redetermine if output flange is renewed ⇒ page 241 .
t
gh ht
pyri by
Vo
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19 - Seal
by
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Prote AG.
❑ For output flange
❑ Replace only with bevel box removed ⇒ page 220
20 - Tapered roller bearing inner race
❑ No replacement part available for this component

21 - Bolt
❑ 25 Nm
22 - Pinion housing
❑ With shaft bevel gear and outer race/tapered roller bearing
❑ No replacement parts available for these components
❑ Carefully lever off and drive in alternately
❑ Observe bolt holes; pinion housing fits only in one position.
23 - O-ring
❑ To renew, unscrew bolts and carefully lever off pinion housing at projecting webs on outside edge.
❑ Do not remove hexagon nut and output flange.
24 - Shim
❑ Observe bevel box bolt bores; shim only fits in one position.
25 - Cap
❑ Drive in to stop with spacer tube - VW 540 1B- .
kswage es n
6.1.2 Assembly overview - components of bevel box, “0CN” ol ot g
byV ua
d ran
ir se tee
o
(Seals, flange shaft mount, output flange au mount in bevel box)
th or
ac
ss
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nl
pt
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1 - Seal
an
itte
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erm
ab
ility
ot p
❑ Between bevel box and
wit
, is n
bevel box
h re
hole
❑ Replacing with bevel
spec
box removed
es, in part or in w
t to the co
⇒ page 219
2 - Bevel box
rrectness of i
l purpos
3 - Oil drain plug

nf
ercia

orm

m
atio
om
❑ 15 Nm
n in
or c
thi
e

t
sd
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rp
cu

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m
f
en
ng

t.
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op py
❑ 15 Nm t. C rig
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pyri by
5 - Seal
co Vo
by lksw
cted agen
Prote
AG.
❑ For right flange shaft

❑ Renewing with gearbox
and bevel box installed
⇒ Rep. gr. 39 ; Oil
seals; Renewing right oil
seal
6 - Breather pipe
❑ Press in until stop is
reached

7 - Cap
8 - Right flange shaft
❑ Removing and installing ⇒ Rep. gr. 39 ; Oil seals; Renewing right oil seal
9 - Seal
❑ To renew, remove needle bearings (polygon bearings) ⇒ Rep. gr. 39 ; Components of bevel box
10 - Needle bearing (polygon bearing)
❑ Needle bearing (polygon bearing) is difficult to turn with flange shaft removed The fact it is difficult to
AG. Volkswagen AG d
move does not mean lkswthat the bearing is defective.
agen oes
not An acoustic test can only be performed with the
bearings installed. byV
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ed ran
❑ Inspect for tho signs of damage to bearings, such as cracking
ris tee
or
in outer race, and renew if necessary.
u
❑ Renewingss a
⇒ Rep. gr. 39 ; Components of bevel box ac
ce
le
un
11 - Locking ring
pt
an
d
itte
y li
erm
ab
❑ For needle roller bearing (polygon bearing)
ility
ot p
wit
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❑ Insert in circumferential groove in stub shaft
h re
ole,
12 - 12-point nut
spec
t to the co
❑ Install using locking fluid - D 000 600- rrectne
❑ Secure nut at three opposing points by peening.
ss o
❑ 350 Nm +_15 Nm
cial p
f inform
13 - Output flange
mer
atio
m

o
n
c
i
or
14 - Shim
thi
te
sd
va
❑ Redetermine if output flange is renewed ⇒ page 241 .

i
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pr
cum
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fo
15 - Seal
en
ng
t.
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op
❑ Renew after removal C py
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rig ht
❑ For output flange py by
co Vo
by lksw
❑ Replace only with bevel box removed ⇒ page 232
cted agen
Prote AG.
16 - Tapered roller bearing inner race

17 - Bolt
❑ 38 Nm
18 - Pinion housing
❑ With shaft bevel gear and outer race/tapered roller bearing
❑ No replacement parts available for these components
❑ Carefully lever off and drive in alternately
❑ Observe bolt holes; pinion housing fits only in one position.
19 - O-ring
❑ To renew, unscrew bolts and carefully lever off pinion housing at projecting webs on outside edge.
❑ Do not remove hexagon nut and output flange.
20 - Shim
❑ Observe bevel box bolt bores; shim only fits in one position.

21 - Cap
❑ Drive in to stop with spacer tube - VW 540 1B- .
6.2 Renewing bevel box seals

⇒ “6.2.1 Renewing seal on bevel box between bevel box and
gearbox”, page 219
⇒ “6.2.2 Renewing output flange oil seal, bevel box 0AV / 0FV
(bevel box removed)”, page 220
⇒ “6.2.3 Renewing output flange oil seal, bevel box 0CN (bevel
box removed)”, page 232
6.2.1 Renewing seal on bevel box between

bevel box and gearbox
♦ Removal tool - T20143-
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♦ Thrust piece - T10298- rrectness o
cial p
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mer
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n
c
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sd
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pr
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ng
t.
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Cop py
♦ Sealing grease ht. rig
rig ht
py by
co Vo
♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
by lksw
cted agen
Prote AG.
– Remove bevel box ⇒ Rep. gr. 34 ; Bevel box; Removing bevel
box .

– Lever seal out using extractor tool - T20143/1- or extractor tool

- T20143/2- .
– Fill half of space between sealing lip and dust lip -arrow- with
sealing grease .
– Drive in seal to stop. AG. Volkswagen AG d

agen oes
lksw not
– Install bevel box ⇒ Rep. gr. 34 ; Bevel box; by VInstalling bevel
o gu
ara
box . orised
nte
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ut ra
– Check gear oil level in bevel box ⇒ss Rep. gr. 39 ; Gear oil .
a c ce
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un
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ot p
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6.2.2 Renewing output flange oil seal, bevel

box “0AV / 0FV” (bevel box removed)
rrectne
• ⇒ “2.2 Distinguishing between different types of bevel boxes”,

s
page 35
s o
cial p
f inform
mer
atio
om
n
c
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pr
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t.
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Cop py
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rig ht
py by
co Vo
by lksw
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Prote AG.


equipment required
AG. Volkswagen AG d
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♦ Support clamp - VW 313-
hole
spec
♦ Tube - VW 516-
es, in part or in w
t to the co
♦ Thrust plate - 40-105-
♦ Thrust piece - T10049- rrectness of i
l purpos
♦ Support plate - T10108/1-

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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Golf 2017 ➤ , GolfautSportsvan
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Cop py
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rig ht
py by
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by lksw
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Prote AG.
♦ Taper roller bearing puller - V.A.G 1582- with short sleeve

♦ Seal located in pinion housing ⇒ page 227 : adapter - V.A.G
1582/6- or adapter - V.A.G 1582/6A-
♦ Two-arm puller - VAS 251 001- , or e.g. two-arm puller - Kukko
20/10-
♦ Seal located on output flange ⇒ page 229 : adapter - V.A.G
1582/13-
♦ Continuation for all
♦ Three-arm puller - VAS 251 205- or e.g. three-arm puller -
Kukko 45-2-
♦ Two-arm puller - VAS 251 001- , or e.g. two-arm puller - Kukko
20/10-
♦ Only for seal in pinion housing ⇒ page 227

AG. Volkswagen AG d
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♦ Only for seal in pinion housing ⇒ page 227
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
e
♦ Extractor hook - VW 771/37-

t
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rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

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nl
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ility
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spec
es, in part or in w
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♦ Seal located on output flange ⇒ page 229

rrectness of i
♦ Press tool - VW 412-

l purpos
♦ Thrust piece - VW 454-

nform
ercia
♦ Installing sleeve - VW 455-

m
at
♦ Thrust plate - VW 401-

om
ion
c
in t
r
♦ or thrust plate - VW 402-

o
his
ate
do
riv
♦ 2 M 8 X 30 mm studs or guide pins M8 - T10273-

p
cum
for
en
g
♦ Not required: pin - VW 460/2-

n
t.
yi Co
op py
♦ Tube - 3296-
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
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es, in part or in w
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♦ Tube - 3296-
rrectness of i
♦ Crankshaft seal installing tool - VW 204 B-

l purpos

nform
ercia

m
a
com
tion in
♦ Sealing grease
r
te o
thi
♦ Universal grease
s
iva
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rp
cum

fo
en
ng
t.
yi Co
♦ 2 x M10 x 30 bolts Cop py
ht. rig
rig ht
♦ 4 x M12 x 10 nuts py by
co Vo
by lksw
cted agen
Prote AG.

Note
♦ The bevel box oil seal for the output flange can only be re‐
newed with the bevel box removed.
♦ The bevel box output flange is provided with a tapered roller
bearing inner race.
♦ This is removed later in the process.
♦ The taper roller bearing for the bevel box output flange and the
shims are not replaced!

– Fit bevel box on gearbox support - T10108- onto hole
-arrow- marked with the number -4-.
A - Lay nuts M12 x 10 (qty. 4) between bevel box and gearbox
support . agen
AG. Volkswagen AG d
oes
olksw not
– Then align bevel box with remaining 3 holes and secure. d by
V gu
ara
ise nte
r
– Place drip tray underneath. ut
ho eo
ra
s a c
s
– Drain oil from bevel box.
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Removing hexagon nut for output flange

– Lock output flange for bevel box with stop plate - T10108/1- .
nform
ercia
Screw in M10 x 30 bolts -arrows- to do this.

m
a
com
t
A - 36 mm socket for 3/4" drive
ion in
r
te o
thi
s
iva
do
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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.
– Swing bevel box so that output flange points upwards.

– Pull output flange together with tapered roller bearing inner
race off shaft bevel gear of bevel box.
A - Three-arm puller - VAS 251 205- or e.g. three-arm puller -
Kukko 45-2-
• Please note different installation positions of seal for output
flange:

Seal -arrow- for output flange is located in pinion housing.

Removing and installing output flange seal in pinion housing
⇒ page 227 .
Seal -arrow- is located on output flange.

Removing and installing output flange seal ⇒ page 229 .
Removing and installing output flange seal in pinion housing:.

Removing seal
– Pull out seal -A- for output flange.
lkswage es n
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byV ua
d ran
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tho
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a ac
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nl
pt
du
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itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

• Bearing inner race/taper roller bearing must be detached from

output flange:
wage
Caution olks es n
ot g
byV ua
d ran
ir se tee
Risk of damage to tapereduth roller bearing inner race.
o
or
a ac
ss
● Pull off tapered roller bearing inner race using adapter -
ce
le
V.A.G 1582/6- or adapter - V.A.G 1582/6A- .

un
pt
an
d
itte
y li
● If tapered roller bearing inner race is damaged, bevel box
rm
ab
must be replaced.
pe
ility
ot
wit
, is n
h re
hole
– Fit thrust plate - 40-105- onto output flange.
spec
es, in part or in w
t to the co
– Pull inner ring/the tapered roller bearing off output flange using
tapered roller bearing puller .
rrectness of i
Note
l purpos
Adapter - V.A.G 1582/6- may be used in place of adapter - V.A.G

1582/6A- .
nform
mercia
a
com
tio
Installing seal and output shaft
n in
r
te o
thi
– Cover pinion housing with a lint-free cloth.
s
iva
do
r
rp
– Clean residual locking fluid from thread of shaft bevel gear. cum
fo
en
ng
t.
yi Co
• If shim -2- was also removed when output flange was re‐ Cop py
moved, it has to be reinserted in pinion housing.
t. rig
gh ht
pyri by
Vo
o
• It assures bearing preload of shaft bevel gear -1- in pinion
c by lksw
cted agen
housing.
Prote AG.
– Lay existing tapered roller bearing inner race -3- in outer race
in bevel box.
– Lightly oil outer circumference of new seal -4- for output flange.
– Drive in new oil seal with thrust piece - T10049- .

• Seal must be flush with upper edge of housing.
– Half-fill space between sealing lip and dust lip with sealing
grease .

– Lightly lubricate splines of output shaft with universal grease .

– Pull in output flange using two arm puller -A-.
A - Two-arm puller - VAS 251 001- , or e.g. two-arm puller - Kukko
20/10-
Please note the following:
. Volkswagen AG
a gen AG does
• Use new or nearly new puller hooks!
Vol
ksw not
gu
y
db ara
• The output flange must not orisbe canted.
e nte
eo
h
ut ra
• Fit puller hooks as farssas they will go onto underside of pinion
a c
housing.
ce
le
un
pt
an
d
• Take up slack on puller hooks fully with two arm puller

itte
y li
erm
-arrows-.
ab
ility
ot p
• Puller hooks should not bend outwards.
wit
is n
h re
ole,
• If necessary, halt pulling process, pull off output flange again
spec
and restart pulling process.
t to the co
Removing and installing output flange seal -arrow-:
Removing seal
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
op
• Bearing inner race/taper roller bearing must be removed in
C py
t. rig
gh
order to remove output flange seal.
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Caution
Risk of damage to tapered roller bearing inner race.

● Pull off tapered roller bearing inner race using adapter -
V.A.G 1582/13- .
must be replaced.

– Remove seal from output shaft.


• To install seal, pinion housing -1- with shaft bevel gear -2- first
has to be removed:
– Unscrew securing bolts for pinion housing -1-; then carefully
lever pinion housing off cross-wise at projecting edges.
– Remove pinion housing with shaft bevel gear -2-.
– Clean thread on shaft bevel gear.
• If shim -3- was also removed when output flange was re‐
moved, it has to be reinserted in pinion housing.
• It assures bearing preload of shaft bevel gear in pinion hous‐
ing.
– Place existing bearing inner race/tapered roller bearing -1- in

pinion housing.
AG. Volkswagen AG d
– Press in new oil seal flush. agen oes
olksw not
y V gu
d b ara
• The larger diameter of crankshaft seal
orise installing tool - VW 204 nte
B- must face towards seal. auth eo
ra
ss c
• Half-fill space between sealing lip and dust lip of seal with
ce
e
nl
pt
sealing grease .
du
an
itte
y li
– Place pinion housing and tapered roller bearing inner race on

erm
ab
ility
output flange.
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Press tapered roller bearing inner race ⇒ page 217 onto output
rrectness of i
flange as far as it will go.

l purpos
• The larger diameter of thrust piece - VW 454- must face to‐

wards output flange.
nform
ercia
• Press in tapered roller bearing inner race only as far as it will

go.
m
at
om
io
• Do not expose the tapered roller bearing to higher forces than

n
c
in t
r
necessary.
o
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.

– Fit shim -2-, tapered roller bearing inner race -3- and pinion
housing -4- onto shaft bevel gear -1-.
• Always reinstall the existing shim -2-.
ing.
– Press output flange and pinion housing plus shaft bevel gear
together as far as they will go.
• Shoulder -arrow- of installing sleeve - VW 455- faces shaft
bevel gear.
lkswage es n
o ot g
byV ua
– Screw in M 8 X r30 ise mm stud bolts = -A- or M8 guide boltsan-te
d r
T10273- into ufinal
tho drive housing. eo
ra
a c
ss
– Lightly moisten new O-ring -1- with gear oil and slide it onto
ce
e
nl
pinion housing -2-.

pt
du
an
itte
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Pinion housing -2- and shim -3- only fit in one position.
erm
ab
ility
ot p
– Install existing shim -3-.

wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Tighten bolts -1- alternately and in small steps. Turn output

flange -2- slightly back and forth while doing so.
– Tighten securing bolts for pinion housing -2- cross-wise.
Coat thread of new hexagon nut with locking fluid D 000 600
– Lock output flange for bevel box with stop plate - T10108/1- .
Screw in M10 x 30 bolts -arrows- to do this.
– Tighten new hexagon nut for output flange ⇒ page 215 .
A - 36 mm socket for 3/4" drive 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
Measure radial run-out on output flange/shaft bevel gear.
ility
ot p
wit
, is n
h re
hole
Note
spec
es, in part or in w
t to the co
After the output flange nut has been tightened, the radial run-out
on the centring pin of the shaft bevel gear must be checked.
– Secure measuring tools with bolt -A- (M8 x 25) on bevel box. rrectness of i
l purpos
– Fit dial gauge - VAS 6080- on centring pin of shaft bevel gear
-B- and set it to “0” with 1 mm preload.
nf
ercia
– Turn output flange one full turn in -direction of arrow-.

rm
m
atio
m
– Read measured value on dial gauge.

o
n in
or c
thi
• Max. radial run-out = 0.05 mm.

te
sd
iva
o
r

rp
cu
o
m
f
en
ng
t.
– Check gear oil level in bevel box ⇒ Rep. gr. 39 ; Gear oil .
yi Co
Cop py
t. rig
Specified torques gh ht
pyri by
Vo
co lksw
by
♦ ⇒ “6.1.1 Assembly overview - components of bevel box, 0AV / Prote
cted AG.
agen
0FV ”, page 215
6.2.3 Renewing output flange oil seal, bevel

box “0CN” (bevel box removed)
• ⇒ “2.2 Distinguishing between different types of bevel boxes”,
page 35


equipment required
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
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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
yri by
op Vo
by c lksw
cted agen
Prote
AG.

♦ Thrust piece - VW 454-
♦ Installing sleeve - VW 455-

lkswage es n
o ot g
byV ua
d ran
ir se tee
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a ac
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
♦ Support rails - VW 457-

ion in
r
te o
thi
♦ Tube - 3296-
s
iva
do
r

rp
cum
fo
en
ng
♦ Support plate - T10108/1-

t.
yi Co
Cop py
. rig
♦ Taper roller bearing puller - V.A.G 1582- with short sleeve
t
gh ht
pyri by
Vo
co
♦ Grip tool - V.A.G 1582/13-
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Crankshaft seal installing tool - VW 204 B-

♦ Thrust plate - 40 - 105-
♦ Socket, 34 mm - T50019-
♦ 2 M 8 X 30 mm studs or guide pins M8 - T10273-
♦ or drip tray for workshop hoist - VAS 6208-
♦ Sealing grease
♦ Universal grease
♦ 2 x bolts M10 x 30
♦ 4 nuts M12 x 10

Note
♦ The bevel box oil seal for the output flange can only be re‐
newed with the bevel box removed.
♦ The bevel box output flange is provided with a tapered roller
bearing inner race.
♦ This is removed later in the process.
♦ The taper roller bearing for the bevel box output flange and the
shims are not replaced!

– Fit bevel box on gearbox support - T10108- onto hole
-arrow- marked with the number -4-.
A - Place nuts M12 x 10 (qty. 4) between bevel box and gearbox
support .
– Then align bevel box with remaining 3 holes and secure.
– Place drip tray underneath.
– Drain oil from bevel box.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Release peened points -arrows- of twelve-point nut -A- from

es, in part or in w
t to the co
indentations of output flange -B- by driving them inwards.

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
Unscrew twelve-point nut for output flange.

en
ng
t.
yi Co
op
– Lock output flange for bevel box with stop plate - T10108/1- . C py
ht. rig
Screw in M10 x 30 bolts -arrows- to do this. rig ht
py by
co Vo
by lksw
A - Socket, 34 mm - T50019- cted agen
Prote AG.

– Swing bevel box so that output flange points upwards.

– Unscrew securing bolts -arrows- for pinion housing -A-.
– Fit a suitable flat-bladed screwdriver -B- into the three recess‐

es -arrows- of pinion housing -A- and carefully lever off pinion
housing together with shaft bevel gear.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
– Position output flange -A- evenly on support rails - VW 457-
ce
e
nl
-arrows-.
pt
du
an
itte
y li
– Press shaft bevel gear off output flange -A-.
erm
ab
ility
ot p
• Prevent shaft bevel gear and tapered roller bearing inner race
wit
, is n
from falling down while doing so.

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Press output flange -A- out of pinion housing.

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.

Note
Seal -arrow- is located on output flange.
• Bearing inner race/taper roller bearing must be removed in

order to remove output flange seal.
AG. Volkswagen AG d
agen
Caution olksw
oes
not
byV gu
ara
ed
is nte
Risk of damage to tapered roller bearing inneruthrace.
or eo
ra
s a c
● Pull off tapered roller bearing inner race using adapter - s
ce
e
V.A.G 1582/13- .
nl
pt
du
an
itte
y li
erm
ab
must be replaced.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Remove seal from output shaft.
rrectness of i
l purpos

– Place existing bearing inner race/tapered roller bearing -1- in
nf
ercia
pinion housing.
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Press in new oil seal flush.
• The larger diameter of crankshaft seal installing tool - VW 204
B- must face towards seal.
• Half-fill space between sealing lip and dust lip of seal with
sealing grease .
– Place pinion housing and tapered roller bearing inner race on
output flange.

– Press tapered roller bearing inner race ⇒ page 217 onto output
flange as far as it will go. agen
AG. Volkswagen AG d
o w es n
olks ot g
• The larger diameter of thrust piece - VW 454-edmust
by
V
face to‐ ua
ran
wards output flange. horis tee
t or
au ac
• Press in tapered roller bearing inner race
ss only as far as it will
go.
ce
e
nl
pt
du
an
itte
• Do not expose the tapered roller bearing to higher forces than
y li
erm
ab
necessary.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Fit shim -2-, tapered roller bearing inner race -3- and pinion
housing -4- onto shaft bevel gear -1-.
rrectness of i
• Always reinstall the existing shim -2-.
l purpos
ing.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Lightly lubricate splines of output shaft with universal grease .

– Press output flange and pinion housing plus shaft bevel gear
together as far as they will go.
• Shoulder -arrow- of installing sleeve - VW 455- faces shaft
bevel gear.
• Turn pinion housing while pressing.

– Screw in M 8 X 30 mm stud bolts = -A- or M8 guide bolts -

T10273- into final drive housing.
– Lightly moisten new O-ring -1- with gear oil and slide it onto
pinion housing -2-.
Pinion housing -2- and shim -3- only fit in one position.
– Install existing shim -3-.
– Tighten bolts -1- alternately and in small steps. Turn output

flange -2- slightly back and forth while doing so.
– Tighten securing bolts for pinion housing -2- cross-wise.
Tighten new twelve-point nut for output flange.

– Lock output flange for bevel box with stop plate - T10108/1- . agen
AG. Volkswagen AG d
oes
Screw in M10 x 30 bolts -arrows- to do this. olksw not
yV g b ua
ed ran
– Tighten new 12-point nut for output flange ⇒ page 217 .horis tee
t or
au ac
A - Socket, 34 mm - T50019- ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Secure twelve-point nut -A-

t to the co
– in indentations (offset by 120°) of output flange -B- by peening

-arrows-.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
240
by c lksw
cted
Rep. gr.39 - Final drive - differential
agen
Prote AG.
Measure radial run-out on output flange/shaft bevel gear.
Note
After the output flange nut has been tightened, the radial run-out
on the centring pin of the shaft bevel gear must be checked.
– Secure measuring tools with bolt -A- (M8 x 25) on bevel box.
– Fit dial gauge - VAS 6080- on centring pin of shaft bevel gear
-B- and set it to “0” with 1 mm preload.
– Turn output flange one full turn in -direction of arrow-.
– Read measured value on dial gauge.
• Max. radial run-out = 0.05 mm. en AG. Volkswagen AG
ag does
lksw not
– Install bevel box ⇒ page
by 41 .
Vo gu
ara
d
ise n
– Check gear oil level
ut
ho in bevel box ⇒ Rep. gr. 39 ;
r
Gear oil . tee o
ra
sa c
Specified torquess
ce
e
nl
pt
du
♦ ⇒ “6.1.2 Assembly overview - components of bevel box, 0CN
an
itte
y li
”, page 217
erm
ab
ility
ot p
wit
6.3 Renewing output flange and redeter‐
, is n
h re
mining thickness of shim
hole
spec
es, in part or in w
t to the co
• The bevel box is removed.
Adjustment is only necessary if the output flange is renewed. Its
purpose is to re-establish the shaft bevel gear tapered roller bear‐ rrectness of i
ing preloading.
l purpos
Bevel box “0AV / 0FV”:

– Remove output flange and pull tapered roller bearing inner
nf
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– Measure length of old and new output flange shafts and de‐
termine difference.
Example:
Old output flange 42.90 mm
New output flange 43.00 mm
Difference 0.10 mm
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Manual Transmision 0GC PDF

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Service

Service Department. Technical Information

All rights reserved.

Copyright © 2018 Volkswagen AG, Wolfsburg D4B806A4276

5.1 Overview of fitting locations - electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.3 Removing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.1 Assembly overview - mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

1.2 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1.3 Removing and installing mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

5.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

10 Front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

10.1 Assembly overview - front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

10.3 Installing front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

2 Oil for front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

2.1 Checking oil level for front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

3 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

3.1 Overview of fitting locations - seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

5 Components of front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

with the ignition switched off.

connecting the battery:

♦ Take the necessary measures when disconnecting the

1.2 Safety measures when working on ve‐

Danger of irreparable damage to gearbox.

♦ If the vehicle must be towed, the selector lever must be in

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 Gearbox identification

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

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

4 Rep. gr.00 - Technical data

3.1 General information

♦ The clutch is burnt or has a mechanical defect.

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- .

♦ Make sure that no dirt can enter an »open« gearbox.

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

♦ If repair work cannot be performed immediately, cover opened

♦ Protect disconnected electrical connectors from dirt and water,

and reconnect them only when dry.

A number of general notes on the individual repair procedures,

Always make sure that no dirt can enter an »open« gearbox. In

areas and then loosen bolts.

tween the engine and gearbox are correctly located.

♦ Do not overstretch retaining rings.

♦ Always renew retaining rings which have been damaged or

6 Rep. gr.00 - Technical data

♦ Check pitch of thread, to ensure correct thread chaser is used

Engine 2.0 l - 110 kW TDI

Dual clutch gearbox 0GC »all-wheel drive«

4.1.3 Golf Estate 2017 ►

Dual clutch gearbox 0GC »all-wheel drive«

4.1.4 Golf SV 2018 ►

8 Rep. gr.00 - Technical data

4.1.5 Tiguan 2016 ►

Dual clutch gearbox 0GC »all-wheel drive«