0GC SM - 4

Service
Workshop Manual
Golf 2018 ➤
7-speed dual clutch gearbox 0GC
cardiagn.com
Edition 01.2018
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Service Department. Technical Information

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

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Contents
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00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.1 General safety provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.2 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 2
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1.3 Notes on tow-starting/towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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1.4 Safety precautions when using testers and measuring instruments during a road test . . . . 2
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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2.1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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3.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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3.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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3.4 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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3.5 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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5.1 Overview of fitting locations - electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Assembly overview - dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Removing and installing clutch end cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3 Removing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4 Installing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1 Mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.1 Assembly overview - mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.3 Removing and installing mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2 Bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.1 Assembly overview - bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.2 Removing bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.3 Installing bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.1 Assembly overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.2 Emergency release from position P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.3 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.4 Moving push-button in the handle to installation position . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.5 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.6 Removing and installing gear selector cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.7 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.8 Checking and adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.9 Renewing oil seal for selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.1 Specified torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.2 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.3 Install gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
5 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
5.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Contents i
Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ➤ , Golf Varia ...
7-speed dual clutch gearbox 0GC - Edition 01.2018
6 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

7 Installing to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
8 Gear oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
8.1 Assembly overview - gear oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
8.2 Removing and installing gear oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
8.3 Removing and installing gear oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
8.4 Removing and installing motor for auxiliary hydraulic pump 1 for gearbox oil V475 . . . . . . 123
9 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
9.1 Overview of oil drain and inspection plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
9.2 Tools for gear oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
9.3 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
9.4 Draining and filling gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

1 Currently, no repairs can be made to gears and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

1 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
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1.1 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.2 Draining and filling gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
2 Oil seals . . .w.ag. e.n.A.G.. V. o. lk. s.w.a.ge. n. A. G. d. o.e.s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
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2.2 Renewing
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2.3 Renewing
au right oil seal . . . . . . . . . . . . . . . . . . . r.ac. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
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3 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
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3.1 Removing and installing right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

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4 Components of bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

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4.1 Assembly overview - components of bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

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4.2 Renewing bevel box seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

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4.3 Renewing right oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

4.4 Renewing left oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

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4.5 Renewing needle bearing for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

4.6 Removing and installing output flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
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1 Safety information
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⇒ “1.1 General safety provisions”, page 1
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⇒ “1.2 Safety measures when working on vehicles with a start/
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stop system”, page 2
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⇒ “1.3 Notes on tow-starting/towing”, page 2
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⇒ “1.4 Safety precautions when using testers and measuring in‐
struments during a road test”, page 2
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1.1 General safety provisions
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To prevent personal injury and damage to or destruction of elec‐
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trical and electronic components, observe the following:

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

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

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

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

with start/stop system.
♦ In vehicles with the start/stop system activated (identifia‐
ble by an indication in the dash panel insert) the engine
can start automatically if required.
♦ When working on the vehicle, always make sure that the
start-stop system is deactivated (switch off the ignition;
switch the ignition on again if necessary).
1.3 Notes on tow-starting/towing
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Caution
Danger of irreparable damage to gearbox.

♦ If the vehicle must be towed, the selector lever must be in
the “N” position, and the vehicle must be towed at a speed
no greater than 50 km/h and agenfor a distance Anot
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It is not possible to tow-start the engine, e.g. if the battery is too

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1.4 Safety precautions when using testers

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test and measuring equipment.

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♦ 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.
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♦ Observe the necessary measures when disconnecting the
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♦ Disconnect battery only after the ignition has been switch‐
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– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
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Disconnecting and reconnecting battery .
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1. Safety information 3
2 Identification
2.1 Gearbox identification

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

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 .
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Gear oil filter change -lks»Yes
wage or no?«
n oes
not
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• The gear oilrisfilter
ed does not have to be changed as aaramatter
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Do not change the filter if:
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♦ The gear oil cooler or its O-rings were renewed and no coolant
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has got into the oil.

rm
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♦ Seals and O-rings of the gearbox were renewed.

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♦ The sump or mechatronic unit were renewed.

hole
spec
♦ The service interval was reached.

es, in part or in w
t to the co
Filter must be changed if:

♦ Metal particles have been found in the oil.
rrectness of i
♦ The clutch is burnt or has a mechanical defect.

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3.2 Rules for cleanliness

nform
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♦ First thoroughly clean connecting points and surrounding

m
areas and then loosen bolts.

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tion in
♦ Seal open lines and connections immediately using clean

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

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

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prevent them from getting dirty. Use sheeting and paper for
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this purpose. Use lint-free cloths only.
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♦ Make sure that no dirt can enter an »open« gearbox.
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♦ Install only clean parts; do not remove Genuine parts from
agen
Prote AG.
packaging until immediately before installing.
♦ If repair work cannot be performed immediately, cover opened
parts carefully.
♦ Protect disconnected electrical connectors from dirt and water,
and reconnect them only when dry.
3.3 General repair instructions

To ensure flawless and successful gearbox repairs, the greatest
care and cleanliness as well as the use of good and proper tools
are essential. Also note the basic rules on safety when performing
repair procedures.
3. Repair instructions 5
AG. Volkswagen AG d
agen oes
ksw n
Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan by Vol
2018 ➤ , Golf Varia ... ot gua
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7-speed dual clutch gearbox 0GC - Edition oris01.2018
e
tee
h
aut or
ac
A ss
number of general notes on the individual repair procedures,
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which can otherwise be found in the relevant sections of the man‐
nl
pt
du
an
ual, are summarised here. They apply for this particular workshop
itte
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manual.
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Guided fault-finding, vehicle self-diagnosis and test instruments
wit
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♦ Before performing repairs to the gearbox, determine the cause
hole
spec
of the fault as accurately as possible ⇒ Vehicle diagnostic
es, in part or in w
tester, Guided Fault Finding , Vehicle Self-Diagnosis
t to the co
or Test Instruments .
Special tool
rrectness of i
For a complete list of special tools used in this workshop manual,
l purpos
see ⇒ "Workshop equipment and special tools" .

Gearbox
nf
ercia
or
Always make sure that no dirt can enter an »open« gearbox. In
m
m
atio
particular, dirt entering an »exposed« mechatronic unit for dual
om
n in
clutch gearbox - J743- and/or oil pump can lead to gearbox failure.
or c
thi
te
♦ If gearbox covers have been unbolted or gearbox has no fluid,
sd
iva
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do not run engine or tow vehicle.

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♦ First thoroughly clean connecting points and surrounding
t.
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op
areas and then loosen bolts. C py
t. rig
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yri by
♦ When installing the gearbox, ensure that dowel sleeves be‐ cop Vo
by lksw
tween the engine and gearbox are correctly located. cted agen
Prote AG.
Locking devices
♦ Do not overstretch retaining rings.
♦ Always renew retaining rings which have been damaged or
overstretched.
♦ Retaining rings must locate properly in grooves.
3.4 Gaskets and seals

♦ Renew O-rings, seals and gaskets.
♦ After removing gaskets and seals, always inspect contact sur‐
face of housing or shaft for burrs resulting from removal or for
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 125 .

3.5 Nuts and bolts

♦ Loosen and tighten securing bolts and securingennut
AG.for
Volcovers
kswagen AG
and housings diagonally. olks
wag does
no
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♦ Specified torques given are for unoiled
ris
ed nuts, bolts and screws. nte
ho eo
ut
♦ Clean threads of bolts which sare
s a to be installed with locking
ra
c
fluid using a wire brush. Then insert bolts with locking fluid -
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un
AMV 185 101 A1- .
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♦ Use a thread chaser to clear residual locking fluid from all
rm
ab
pe
threaded holes into which self-locking bolts are to be screwed.
ility
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Otherwise there is a danger of bolts shearing when subse‐
wit
, is n
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quently being removed.
hole
spec
♦ Check pitch of thread, to ensure correct thread chaser is used
es, in part or in w
to clean threads and to ensure the threads are not damaged.
t to the co
♦ Always renew self-locking bolts and nuts.
rrectness of i
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mercia
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3. Repair instructions 7
AG. Volkswagen A
Golf 2017 ➤ , Golf Sportsvano2015 agen
ksw ➤ , Golf Sportsvan 2018
es n ➤ , Golf Varia ...
G do
V l ot g
7-speed dual clutch gearbox
ed b 0GC - Edition 01.2018
y ua
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4 Technical data
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pt
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erm
ab
4.1 Allocation gearbox - engine
ility
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hole
spec
4.1.1 Golf SV 2015 ►
es, in part or in w
t to the co
Take account of the gearbox code if spare parts are required for
a repair.
rrectness of i
Dual clutch gearbox 0GC, front-wheel drive
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Codes RAU, SKZ, SWU

Engine 2.0 l - 110 kW TDI
nform
ercia
4.1.2 Golf 2017 ►

m
at
om
ion
c
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If genuine parts are required for a repair, always refer to the gear‐
or
his
e
box code.
at
do
priv
cum
or
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Dual clutch gearbox 0GC »front-wheel drive«
f
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Codes RAU, SKZ, SWU
t. Cop
RAU, SKZ, SWU py
rig RMV
gh
Engine 2.0 l - 110 kW TDI 2.0 l - 135 kW TDI 2.0 I - 180 kW TSI
ht
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Prote AG.
Dual clutch gearbox 0GC »all-wheel drive«

Codes SWR
4.1.3 Golf Estate 2017 ►

If genuine parts are required for a repair, always refer to the gear‐
box code.
Dual clutch gearbox 0GC »front-wheel drive«
Codes RAU, SKZ, SWU RAU, SKZ, SWU
Engine 2.0 l - 110 kW TDI 2.0 l - 135 kW TDI
Dual clutch gearbox 0GC »all-wheel drive«

Codes RAV, SKY, SWR SWR
Engine 2.0 l - 135 kW TDI 2.0 l - 110 kW TDI
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

4.2 Capacities
Capacity Dual clutch gearbox 0GC
Initial filling 6.8 l ± 0.1 l
Changing approx. 6 l
♦ Change interval: ⇒ Maintenance manual and/
or ⇒ service tables “ELSA”
Lubricant Dual clutch gearbox oil
Capacity Front bevel box

Initial filling approx. 0.85 l
Changing Filled for life, no change
Lubricant Gear oil
The oil is available as a replacement part; part no. ⇒ Electronic
parts catalogue (ETKA) .
Further information in the part number designates the container
cardiagn.com
size.
AG. Volkswagen AG d
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wit
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es, in part or in w
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4. Technical data 9
7-speed dual clutch
wage
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AG. Volksw0GC
agen A-GEdition 01.2018
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Vol t gu
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Electrical components
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5.1 Overview of fitting locations - electrical components
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1 - Mechatronic unit for dual
h re
clutch gearbox - J743-
hole
spec
❑ Removing and installing
es, in part or in w
t to the co
⇒ page 29
2 - Gearbox input speed send‐
er - G182- and oil temperature
rrectness of i
sender in multi-plate clutch -
l purpos
G509-
❑ Not for this model
nform
ercia
3 - Selector lever - E313-

m
❑ With selector lever sen‐
at
om
io
sors control unit - J587- ,
n
c
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selector lever lock sole‐

o
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t
noid - N110- and selec‐

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tor lever locked in posi‐

p
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tion P switch - F319-

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❑ The components are in‐ t. Cop py
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rig
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circuit of the selector op Vo
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mechanism and cannot cted agen
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be renewed separately
❑ Checking ⇒ vehicle di‐
agnostic tester
selector mechanism
⇒ page 52

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

Replacement parts
1 - Retaining ring for dual

clutch end cover
❑ Renew after removal
2 - Retaining ring for dual
clutch
cardiagn.com
3 - Retaining ring for drive plate
4 - Dual clutch
❑ Removing ⇒ page 15
❑ Installing ⇒ page 18
5 - Shims
❑ 10 spacer rings which n AG. Volkswagen AG do
have different lkswage
»thick‐ es n
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by ua
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in 0.05hor mm increments.
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❑ Thickness
ss
a of spacer ring ac
must be determined
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pt
when installing dual

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clutch.
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6 - Dual clutch end cover

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h re
hole

spec
⇒ page 11
es, in part or in w
t to the co
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c
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1.2 Removing and installing clutch end cov‐

p
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Cop py
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Special tools and workshop equipment required
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1. Clutch 11
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♦ Clean assembly sleeve - T10459- before using. ris Do not
e
use a tee
ho
scratched sleeve. aut or
ac
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t to the co
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Removing
ss
• Cover and retaining ring must always be renewed.
o
cial p
f inform
– Drain gear oil ⇒ page 125 .
mer
atio
– Remove gearbox ⇒ page 65 .
om
n
c
i
or
n
– Secure gearbox in a vertical position on engine and gearbox
thi
te
support ⇒ page 118 .
sd
a
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iv
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pr
cum
r
– Renew gear oil filter ⇒ page 122 .

fo
en
ng
t.
yi Co
– Lever out retaining ring -2- of clutch end cover using screw‐ Cop py
driver -1- -arrow- and remove.
ht. rig
rig ht
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co Vo
by lksw
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Prote AG.
12 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
cardiagn.com
Caution
Cover and retaining ring must always be renewed.

. Volkswage AG n AG d
agen o
Never grasp a new cover in centrey Vseal.
olks The centre hole of the s not g
w e
cover must not be touched, oiled ed or brought into contact with
b ua
ran
ris
other materials. Leaks will uresult.
tho tee
o ra
sa c
Never install new coverss with a hammer!
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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– Only handle cover as shown -in this picture-.

wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
There must be no stickers on the inside of the cover. If, however,

stickers are present, remove them carefully.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
c
– The running surface on the end of the shaft of the clutch

or
thi
-arrow- must be free of oil and dry.

te
sd
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– If necessary, thoroughly clean running surface.

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WARNING
C py
t. rig
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co
The centre seal of the new cover must be »preformed« before
by lksw
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Prote
installing:
AG.
1. Clutch 13
– 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‐. Volkswag
en AG
stallation position. ksw
agen
AG does
n ol ot g
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– Remove sleeve upwards out of cover and set ed sleeve on end
b ua
ran
ris
of clutch shaft. tho tee
or
au ac
– Moisten outer seal of cover with oil. ss
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nl
pt
du
an
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itte
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Caution
erm
ab
ility
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Moisten only the outer seal of the cover with oil. Oiling the inner
wit
, is n
seal will always cause leaks.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
– Guide cover horizontally over sleeve and press evenly onto its
or
seat.
m
m
atio
om
n in
c
Caution
or
thi
te
sd
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o
r
Work carefully. Any sort of blow to the cover is certain to cause

rp
cu
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leaks.
f
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ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
It is possible to lever cover carefully into its seat with a

-screwdriver- until »new« retaining ring can be installed.
– Install new retaining ring.

– Do not remove bush until retaining ring is installed.

– Installing gearbox ⇒ page 111
– Top up gear oil ⇒ page 130 .
WARNING
Do not start engine if there is no oil in gearbox.
– After installation of gearbox, initiate default settings by

means of Guided Functions ⇒ vehicle diagnostic tester .
1.3 Removing dual clutch

♦ 2 x hooks - 3438-
cardiagn.com
♦ Puller - T10055-
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♦ Puller - T10525-
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
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or
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Brief description
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pr
cum
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fo
• The axial play of the clutch is readjusted during installation

en
ng
t.
procedure.
yi Co
Cop py
ht. rig
rig ht
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15
co Vo
by lksw
cted
1. Clutch
agen
Prote AG.
• To remove or install clutch, gearbox must be securely attached

to an assembly stand in vertical position ⇒ page 118 . Only
this way is it possible later to adjust axial play of the clutch
without error.
Removing
– Remove clutch end cover ⇒ page 11 .
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
cardiagn.com
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-.
lkswage es n
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spec
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t to the co
rrectness of i
l purpos
nform
mercia
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tion in
r
te o
thi
s
iva
do
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cum
fo
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Apply puller - T10525- together with puller - T10055- on

splines and carefully pull drive plate off its seat -arrows-.
– Remove retaining ring -arrow- and save it for now.
cardiagn.com
Note
Do not dispose of the retaining ring yet because it will be needed

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

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Caution
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wit
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Carefully remove the dual clutch. Take care that no parts fall
hole
spec
out. Therefore, do not turn the clutch over!

es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
– Engage 2 hooks - 3438- on opposite sides of clutch -arrow-.

orm
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atio
om
n in
or c
thi
te
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1. Clutch 17
– Remove dual clutch using hooks - 3438- .
AG. Volkswagen AG d
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1.4 Installing dual clutch
ility
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♦ Universal dial gauge holder - VW 387-
t to the co
rrectne
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ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
♦ Dial gauge - VAS 6079-

en
ng
t.
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Cop py
t. rig
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Prote AG.
♦ Retaining pins - T10524-

♦ Thrust piece - T10526-
lkswage es n
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Caution
♦ The drive plate has to remain engaged between the teeth
rrectness of i
of the outer plate carrier.
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♦ If the drive plate detaches, the plates in the dual clutch can
shift. It may then not be possible to adjust the clutch cor‐
nform
ercia
rectly when it is installed.
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m
♦ Do not lift (not even slightly) or remove plate carrier! The
at
om
io
plates could turn.
n
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ate
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Brief description
p
cum
for
en
ng
t.
• To remove or install the clutch, the gearbox must be securely
yi Co
op
attached to an assembly stand in vertical position.
C py
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• The large plate carrier goes through all plates inside the clutch. cop Vo
by lksw
It must not slip out of the lowest plate.
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Prote AG.
Installing
– Take great care when removing the dual clutch from its pack‐
age.
– Turn piston rings by hand. They must move freely and must
not bind.
– 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 19
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.
cardiagn.com
– Carefully insert -dual clutch-, ensuring it does not fall.
– If necessary, insert clutch by turning slightly.
AG. Volkswagen AG d
agen oes
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ility
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The dual clutch is properly fitted if there is almost no play in the

hole
spec
retaining pin - T10524- .

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

m
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om
ion
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or
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ate
do
priv
cum
for
en
ng
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

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

-1- -arrow-.
Note
This retaining ring will be used again. Do not dispose of it.
– Apply puller - T10525- together with puller - T10055- on
cardiagn.com
splines and carefully pull drive plate off its seat -arrows-.
Note
The retaining pin - T10524- must be held by a second mechanic

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

place it on one side.
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Do not lift (not
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Determining shim for dual clutch:

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Before this ring is finally disposed of, 3 measurements must be

made.
First measurement (axial play of shaft)
rrectness of i
– Screw universal dial gauge - VW 387- to gearbox flange.

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1. Clutch 21
– 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
cardiagn.com
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.
AG. Volkswagen AG d
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Second measurement by Vo gu
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• The retaining pin - T10524- remains
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– 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.
cardiagn.com
WARNING
Always use the next-largest shim, never the next-smallest.
Example: wage
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Calculated dimension for shim New
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– Remove old retaining ring -arrow-.
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Note
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Do not dispose of ring yet; it will be needed once more.

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– Fit calculated shim.

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Third measurement (check measurement)

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To make sure that the shim is correct, a test measurement must

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• The retaining pin - T10524- remains installed!
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1. Clutch 23
– Install old retaining ring -arrow- once more.
– Set tip of dial gauge -on hub of large plate carrier-.
Note
Set the tip of the dial gauge on the shim -1-.
– Set -dial gauge- to 0 with preload again.
cardiagn.com
– Lift dual clutch with force to stop and note measurement.
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– Call this value “C”. lksw
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Now calculate which rise shim must finally be fitted:
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– Use this formula:
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Value “C” minus value “A” = specification

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This specification must lie between 0.05 and 0.12 mm.

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– Install new retaining ring -arrow-.

es, in part or in w
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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, align these.
– A second mechanic must hold retaining pin - T10524- in its
place and press outwards slightly.
– Carefully drive the drive plate onto its seat using press tool -
40-21- and a plastic hammer.
– Install drive plate retaining ring.
– Starting at the opening, press retaining ring in clockwise di‐
rection into its fitting position.
• The retaining ring must be fully engaged.
– Use screwdriver to check that retaining ring is correctly seated
and engaged.
– Now remove retaining pin - T10524- from between dual clutch
and housing.
– Install clutch end cover ⇒ page 11 .
cardiagn.com
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1. Clutch 25
34 – Controls, housing
1 Mechatronic unit
⇒ “1.1 Assembly overview - mechatronic unit”, page 26
⇒ “1.2 Removing and installing sump”, page 27
⇒ “1.3 Removing and installing mechatronic unit”, page 29
1.1 Assembly overview - mechatronic unit

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1 - Gearbox e d b ara
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2 - Mechatronicauunit
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clutch gearboxs - J743-
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⇒ page 29
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3 - Bolt
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❑ Tightening sequence
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⇒ page 27
hole
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4 - Seal
❑ Renew after removal rrectness of i
5 - Bolt
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❑ 8 Nm + 60°
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⇒ page 27
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26 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
1.2 Removing and installing sump
cardiagn.com
♦ Used oil collector and extractor - VAS 6622 A-
AG. Volkswagen AG d
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Removing
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– Move selector lever to position “P”.

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

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1. Mechatronic unit 27
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♦ Do not run engine or tow vehicle with sump removed or
ab
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when there is no gear oil in the gearbox.
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spec
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Removing and installing noise
t to the co
insulation .
Vehicles with petrol engine
rrectne
– Remove connecting hose between charge air cooler and
charge air pipe ⇒ Rep. gr. 21 ; Charge air system; Assembly
ss
overview - charge air system .
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Continued for all vehicles
form
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– Remove electrical wiring and retainers from sump at front Prote AG.
-arrows-.
– Raise wiring in area of sump and secure it.
Caution
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-. . Volkswage
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– Unscrew boltsy V-1-
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– Remove ho sump -2-. If necessary, lightly strike sump with
ris nte
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s aut hammer to loosen. ra
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Installing
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Install in reverse order of removal, observing the following:
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• Always renew the sump, the sump bolts and the retaining clip.
spec
• Renew O-ring -arrow- on connector for mechatronic unit for
t to the co
dual clutch gearbox - J743- .
rrectne
Note
ss
When renewing the mechatronic unit for dual clutch gearbox -
cardiagn.com
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J743- , the O-ring will be supplied together with the new replace‐
inform
ment part.
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– Remove any oil and grease from sealing surface on gearbox n

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

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– Install new securing clip -3-.
AG.
• Offset side of retaining clip faces gearbox.

– Fit connector for mechatronic unit and engage.
– Top up gear oil and check gear oil level ⇒ page 125 .
Specified torques
♦ ⇒ “1.1 Assembly overview - mechatronic unit”, page 26
1.3 Removing and installing mechatronic

unit
Removing
Always make sure that no dirt can enter an »open« gearbox.
In particular, dirt entering an »exposed« mechatronic unit and/or
oil pump can lead to gearbox failure.
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 27 .
– Unscrew bolts -arrows- in a diagonal sequence.

– Remove mechatronic unit -1- carefully.
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Holding and carrying mechatronic unit auth or
ac
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ss
– Remove mechatronic unit for dual clutch gearbox - J743- .
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Laying mechatronic unit to side properly

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– Put down mechatronic unit so that sensors -arrows- are point‐

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ing upwards.
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Installing
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• 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 27 .
– Install sump ⇒ page 27 .

– Top up gear oil and check gear oil level ⇒ page 125 .
– Adopt basic setting for mechatronic unit:
cardiagn.com
– Connect ⇒ Vehicle diagnostic tester and start Guided Func-
tions .
♦ 02 Gearbox electronics
♦ 02- Basic setting
Specified torques
♦ ⇒ “1.1 Assembly overview - mechatronic unit”, page 26
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2 Bevel box
⇒ “2.1 Assembly overview - bevel box”, page 32
⇒ “2.2 Removing bevel box”, page 33
AG. Volkswagen AG d
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⇒ “2.3 Installing bevel box”, page 39 olksw not
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2.1 Assembly overview - bevel box ris nte
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1 - Bolt
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❑ 25 Nm
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2 - Heat shield
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❑ For drive shaft.
❑ If present
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3 - Nut
❑ Qty. 2 or 3
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❑ If present
cardiagn.com
s
❑ Specified torque ⇒ Run‐
s o
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ning gear, axles, steer‐
f in
ing; Rep. gr. 40 ; Sub‐
form
mer
frame; Assembly over‐
atio
m
view - subframe .
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4 - Bolt
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❑ 40 Nm
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❑ 20 Nm Prote AG.
7 - Bevel box
❑ Removing ⇒ page 33
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 64
11 - Bolt
❑ Qty. 2
❑ Bevel box carrier to engine
❑ Specified torque and tightening sequence: ⇒ page 64

2.2 Removing bevel box
2.2.1 Removing bevel box, Golf 2017 ►, Golf

Estate 2017 ►, vehicles with diesel en‐
gine
n AG. Volkswagen A age G do
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♦ Socket insert - T10107 A- by Vol ot g
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♦ Counter-hold tool - T10172A-
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♦ Engine support - T50015A- cted agen
Prote AG.
2. Bevel box 33
♦ Bracket - T10533/2-
♦ Bolt - T10533/4-
♦ Hexagon key extension, 8 mm - 3247-
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♦ Torque wrench - V.A.G 1331-
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♦ Flange bolt M8 x 30 mm
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♦ Grease for clutch plate splines ⇒ Electronic Parts Catalogue t. C rig
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Removing
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Prote AG.
– 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
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– Separate connector -1-.

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– Unscrew bolt -2- and push auxiliary pump for heating - V488-
erm
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to right side. Do not disconnect any lines ⇒ Rep. gr. 19 ;
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Coolant pump, regulation of cooling system; Assembly over‐
wit
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view - electric coolant pump .
h re
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spec
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .
t to the co
cardiagn.com
rrectness o
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f i
– If fitted, remove drive shaft heat shield -1- from bevel box
nform
-arrows- ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive

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

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Caution
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Risk of damage to flexible joint. C py
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♦ Observe ⇒ Rep. gr. 26 ; Emission control; Assembly
cop Vo
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overview - emission control . cted agen
Prote AG.
– Remove clamp -2- from front exhaust pipe ⇒ Rep. gr. 26 ;

Exhaust pipes/silencers; Assembly overview - silencer .
Disregard bolts -1-.
2. Bevel box 35
– Unscrew bolts -arrows- on bevel box, and remove heat shield

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

output shaft of bevel box -arrows-.
AG. Volkswagen AG d
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– Unbolt front propshaft from bevel box -arrows-.
t to the co
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– If necessary, counterhold at rear final drive when loosening or

f
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t.
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tightening propshaft.
Co
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Note Prote
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agen
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.
– When pulling off or pushing on propshaft, always ensure that

sleeve -arrow- is not damaged.
– Push pendulum support to one side.
cardiagn.com
– 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.
AG. Volkswagen AG d
– Tighten bolts by hand. agen oes
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– Push engine with engine support - oT50015-
ris
ed
as far forwards as nte
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– Ensure that coolant hoses are not trapped between engine
ce
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nl
pt
and radiator.
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– Pull propshaft off bevel box, and lay it on subframe.

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– Unscrew bolts -A- and -B-, and remove bevel box carrier -1-.
h re
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es, in part or in w
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c
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Prote AG.
2. Bevel box 37
– Remove countersunk bolt for right flange shaft with socket -

T10107 A- .
– To do this, screw 2 bolts into flange and counterhold flange

shaft with an assembly lever.
Renew countersunk bolt after removal.
cardiagn.com
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-
♦ Bolt -2- is located in vicinity of stud with hexagon drive -B-
♦ The front exhaust pipe with catalytic converter
agen
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– Unscrew upper securinghobolts
ris -1- and -2- for securing bevel tee
box to gearbox. s aut or
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– Unscrew lower bolts -arrows- securing bevel box to gearbox.

– Carefully press off bevel box and remove.
rrectness of i
– Install bevel box ⇒ page 39 .

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Rep. gr.34 - Controls, housing
2.3 Installing bevel box
Note
♦ Refer to section “Removing bevel box” for required special

tools ⇒ page 33 .
♦ 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
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AG. Volkswagen AG d
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– Before joining bevel box and gearbox, insert
d b “new” securing
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bolts -arrows- into bevel box at top. orise
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nte
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– Push bevel box (with new securing ss bolts fitted at top) com‐
a c
pletely onto gearbox, ensuring that splines of bevel box input
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shaft and differential are centred when brought together.
du
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– If splines are correctly positioned and shafts are centred, then
ab
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bevel box will slide to stop against gearbox.
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Note
es, in part or in w
t to the co
Do not use securing bolts to pull bevel box onto gearbox, or bevel
box will cant and bolt holes can break off.
rrectness of i
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Access to the upper bolts securing the bevel box to the gearbox
may be restricted depending on engine version.
nform
ercia
Arrangement of upper bolts (-1- and -2-) for securing bevel box
to gearbox (hidden by bevel box).
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♦ Bolt -1- is located in vicinity of bolt -A-

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♦ 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

um
for
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-C- is located above the bolts.

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Prote AG.
2. Bevel box 39
– Tighten upper and lower bolts -arrows- for securing bevel box
to gearbox. Specified torque: ⇒ page 64 .
– Bolt bevel box carrier to engine and bevel box, observing tight‐
cardiagn.com
ening sequence ⇒ page 64 .
– Secure flange shaft with new countersunk bolt. Specified tor‐ agen
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– Fit propshaft on bevel box. rise nte
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Note
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When removing and installing the bevel box, do not damage the
ss
seal in the propshaft flange -arrow-. Renew propshaft if damaged.

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mer
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– Bring bevel box and propshaft together by turning spindle of

engine support - T50015- -A-.
lkswage es n
– When joining parts, ensure by V that markings -arrows- on flexible
o ot g
ua
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coupling align with output
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– au
Remove enginesssupport - T50015A- . ac
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, is n
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hole
spec
es, in part or in w
t to the co
– Bolt propshaft to bevel box -arrows- ⇒ Propshaft and rear final
rrectness of i
drive; Rep. gr. 39 ; Propshaft; Removing and installing prop‐
l purpos
shaft .
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– Bolt on heat shield -1- . Specified torque: ⇒ page 32 cop Vo
by lksw
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Prote AG.
2. Bevel box 41
– Secure pendulum support to gearbox using new bolts -1-.

Specified torque ⇒ Rep. gr. 10 ; Assembly mountings; As‐
sembly overview - assembly mountings
– Fit front exhaust system to engine ⇒ Rep. gr. 26 ; Exhaust
pipes/silencers; Assembly overview - silencer . AG. Volkswagen n AG do
ks wage es n
– Install right drive shaft ⇒ Running gear, axles,
Vol steering; Rep. ot g
by ua
gr. 40 ; Drive shaft; Removing and installing
ris
ed drive shaft . ran
tee
tho or
s au ac
s
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pt
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ab
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– Mount drive shaft heat shield -1-, if present, on bevel box
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(-arrows-) ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive
h re
hole
shaft .
spec
es, in part or in w
Right drive shaft heat shield is secured with 2 or 3 nuts.
t to the co
Continue installation in reverse order of removal.
rrectness of i
– Check gear oil in bevel box ⇒ page 134 .
cardiagn.com
l purpos
– Install noise insulation ⇒ General body repairs, exterior; Rep.

gr. 66 ; Noise insulation; Assembly overview – noise insula‐
tion .
nform
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at
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ion
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ate
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Prote AG.

3 Selector mechanism
⇒ “3.1 Assembly overview - selector mechanism”, page 43
⇒ “3.2 Emergency release from position P”, page 44
⇒ “3.3 Removing and installing selector lever handle”,
page 45
⇒ “3.4 Moving push-button in the handle to installation position”,
page 51
⇒ “3.5 Removing and installing selector mechanism”, page 52
⇒ “3.6 Removing and installing gear selector cable”, page 56
⇒ “3.7 Checking selector mechanism”, page 58
⇒ “3.8 Checking and adjusting selector lever cable”, page 59
⇒ “3.9 Renewing oil seal for selector shaft”, page 60
3.1 Assembly overview - selector mechanism
cardiagn.com
1 - Handle with selector cover
❑ Do not remove handle
without reason. For
emergency release, on‐
ly the cover needs to be
unclipped ⇒ page 44 .
⇒ page 45
2 - Bolt
❑ Qty. 4
AG. Volkswagen AG d
❑ 8 Nm agen oes
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3 - Selector mechanism orise nte
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❑ With integrated selector s au ra
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lever sensor control unit s
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- J587- with selector lev‐

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itte
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switch - F189- , switch

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for selector lever locked

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lever lock solenoid -

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spec
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⇒ page 52
4 - Securing clip
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❑ Always renew after re‐

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moving.
5 - Nut
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❑ Qty. 4
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❑ For selector mechanism

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to body
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❑ 8 Nm
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6 - Selector lever cable

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❑ Removing and installing ⇒ page 56
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❑ Checking and adjusting ⇒ page 59 Prote
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3. Selector mechanism 43
AG. Volkswagen AG d
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Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golfised b Sportsvan 2018 ➤ , Golf Varia ... uaran
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7-speed dual clutch gearbox 0GC - Edition
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7 - Bolt
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❑ Adjuster screw for selector lever cable
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❑ 13 Nm
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8 - Cover
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❑ Always renew after removing.
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9 - Bolt
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❑ Qty. 2
❑ 20 Nm
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10 - Retaining clip
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❑ Installation position: offset side of retaining clip faces gearbox selector lever
nform
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11 - Cable support bracket

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❑ For selector lever cable
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12 - Grommet
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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 p by
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14 - Nut Prote AG.
15 - Bolt
❑ 10 Nm +90°
16 - Gearbox selector lever
3.2 Emergency release from position P

Do not remove knob.
Golf, Golf Estate:
– Using both hands, grasp into gear lever gaiter on left and right
-arrows-, and pull up selector cover -1- to unclip it.

Golf SV:
– Using wedge - T10383- , carefully lever gear lever gaiter off
centre console insert -arrows-.
Continuation for all:
– Depress brake pedal or set handbrake.
– Push selector cover to one side.
AG. Volkswagen AG d
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– Using a screw driver, from right
oris side, press yellow plastic part
e nte
and hold in this position. auth eo
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Selector lever can now be moved from position »P«.
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Clip in selector cover:
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Golf, Golf Estate:
h re
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hole
spec
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Caution
t to the co
The selector cover is surrounded by a chrome frame. Under
no circumstances should pressure be applied to the chrome
rrectness of i
frame during installation. Risk of damage.
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nf
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– Start by inserting selector cover -1- at rear. Then, without ap‐
or
plying direct pressure to chrome frame, engage it in centre
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console at front.
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3.3 Removing and installing selector lever

handle
⇒ “3.3.1 Removing and installing selector lever handle, Golf
2017 ►, Golf Variant 2017 ►”, page 45
⇒ “3.3.2 Removing and installing selector lever handle, Golf SV
2015 ►, Golf SV 2018 ►”, page 48
3.3.1 Removing and installing selector lever

handle, Golf 2017 ►, Golf Variant 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. wage
cardiagn.com
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– Cut open clamp -arrow- under boot using side cutters.
es, in part or in w
t to the co
rrectness of i
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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.
Note
Do not press button again after removal as it will otherwise no

longer be possible to install the handle.
Installing
• Selector lever is in position “D”.
AG. Volkswagen AG d
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Note
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♦ It might be possible for the push-button to be pressed into the

inform
handle. Never install a handle with the push-button pressed

mer
in.
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♦ Move push-button to installation position ⇒ page 51 .

c
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or
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♦ New handle is supplied with installation guard. Do not remove

sd
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guard until just before installing. To remove, pull out

p
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-in direction of arrow-.

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Cop py
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– Push handle fully onto selector lever and lock.
rig
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– Push sleeve downwards to lock.
lksw
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Prote AG.
Handle with clamp:

– Push on handle with new clamp -arrow- to stop.
– Secure clip with hose clip pliers - V.A.G 1275 A- .
– Connect electrical connector.
– Push push-button after installation.
Note
If not installed correctly, the button remains inserted in the handle

after being pressed. If this happens, remove handle again and
move push-button to installation position again ⇒ page 51 .
Then fit the handle again.
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.
cardiagn.com
– 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
agen oes
olksw not
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rise nte
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3.3.2 Removing and installing selector lever

nl
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du
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handle, Golf SV 2015 ►, Golf SV 2018 ►

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erm
ab
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wit
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♦ Hose clip pliers - V.A.G 1275 A-

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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Prote AG.

♦ Wedges - T10383-
Brief description
Handle is removed together with selector cover.
Removing
– Using wedge - T10383- , carefully lever gear lever gaiter off
centre console insert -arrows-.
– Separate electrical connector.
cardiagn.com
AG. Volkswagen AG d
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nl
pt
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– Cut open clamp -arrow- under boot using side cutters.

erm
ab
ility
ot p
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hole
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es, in part or in w
t to the co
rrectness of i
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Cop py
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Prote AG.
Pull off handle upwards without pressing push button -arrow-.

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

longer be possible to install the handle.
Installing
• Selector lever is in position “D”.
lkswage es n
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un
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Note a
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tion in
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♦ It might be possible for the push-button to be pressed into the

thi
s
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handle. Never install a handle with the push-button pressed

do
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in.
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♦ Move push-button to installation position ⇒ page 51 .
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Cop py
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♦ New handle is supplied with installation guard. Do not remove
gh ht
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guard until just before installing. To remove, pull out cop Vo
by lksw
-in direction of arrow-.
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Prote AG.
– Push handle fully onto selector lever and lock.

– Push sleeve downwards to lock.

Handle with clamp:

– Push on handle with new clamp -arrow- to stop.
– Secure clip with hose clip pliers - V.A.G 1275 A- .
– Connect electrical connector.
– Push push-button after installation.
Note
If not installed correctly, the button remains inserted in the handle

after being pressed. If this happens, remove handle again and
move push-button to installation position again ⇒ page 51 .
Then fit the handle again.
– Clip cover in position.
3.4 Moving push-button in the handle to in‐
cardiagn.com
stallation position
If the button was pressed by mistake, the installation position can
be restored.
There are 2 ways of moving the push button into the installation
position, »with« and »without« installation guard. Both of them are
described here.
Place handle »with« installation guard in installation
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AG. Volkposition:
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do w es n
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When using the installation guard,edmake by
V
sure that it has an eyelet ua
ran
-arrow- at the front. Other typeshorisof installation guard are not suit‐ tee
able. au
t or
ac
ss
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nl
pt
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itte
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ab
ility
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Holding down push button, completely push in installation

guard with eyelet -arrow- until installation guard engages, then
l purpos
release push button. When the installation guard is pulled out,

the push-button engages in the installation position.
nf
ercia
Place handle »without« installation guard in installation position:

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Prote AG.
– Carefully unclip handle trim -A- upwards.
– Using e.g. a screwdriver press small lever -1- for pull rod into
cardiagn.com
groove -2-. This action presses the push button -3- back into
installation position. gen AG
. Volkswagen AG
d a oes
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-I- = button pressed in Vol gu
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-II- = button in installation position
tho eo
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Note
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♦ Press the lever only into the groove and no further.
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ility
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♦ Do not clip the handle trim onto selector mechanism until the
handle has been fitted. This makes it possible to check wheth‐ h re
hole
spec
er the small lever engages in the pull rod when the push-button
es, in part or in w
is pressed.
t to the co
3.5 Removing and installing selector mech‐

rrectness of i
anism
l purpos
⇒ “3.5.1 Removing and installing selector mechanism with selec‐

nform
ercia
tor lever cable”, page 52

m
⇒ “3.5.2 Removing and installing selector mechanism without se‐

a
com
tio
lector lever cable”, page 54

n in
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3.5.1 Removing and installing selector mech‐

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anism with selector lever cable

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Special tools and workshop equipment required t. Cop py
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♦ Release lever - 80-200-
AG. Volkswagen AG d
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Brief description ed by
V gu
ara
ris nte
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In the interior, the centreaut console must be removed.
h eo
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The heat shield beneath the vehicle must be removed.
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nl
pt
du
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Removing
itte
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erm
ab
– Remove selector lever handle ⇒ page 45 .
ility
ot p
cardiagn.com
wit
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– Remove centre console ⇒ General body repairs, interior; Rep.
h re
gr. 68 ; Centre console; Removing and installing centre con‐
hole
spec
sole .
es, in part or in w
t to the co
– If fitted, remove footwell air duct ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air duct; Assembly overview - air routing and air
distribution in passenger compartment .
rrectness of i
– Separate electrical connector from selector mechanism to ve‐
l purpos
hicle wiring harness.

– Remove air filter housing ⇒ Rep. gr. 23 ; Air filter; Removing
nf
ercia
and installing air filter housing orm

m
atio
– Push ball socket -1- of selector lever cable off gearbox selector
om
lever using removal lever - 80-200- .

n in
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– Unscrew bolts -2- for cable support bracket.

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– Do not bend or kink cable.

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– Install centre tunnel heat shield below selector mechanism ⇒ Cop py
General body repairs, exterior; Rep. gr. 66 ; Mouldings/trims/
t. rig
gh ht
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extensions; Removing and installing floor heat shield .
p by
o Vo
by c lksw
cted agen
Prote AG.
– Remove bracket -A- if present.

– Remove nuts -arrows- inside vehicle.
– Remove selector mechanism -B- together with selector lever
cable and selector housing downwards.
Installing
Install in reverse order of removal. During this procedure, observe
the following:
Note
♦ Do not bend or kink gear selector cable.

♦ Do not grease selector lever cable.
♦ Following installation of selector mechanism, selector lever
cable must be checked for ease of movement and be adjusted.
– Install heat shield below selector mechanism ⇒ General body

repairs, exterior; Rep. gr. 66 ; Mouldings/trims/extensions;
Removing and installing floor heat shield .
cardiagn.com
– If featured, install footwell air duct ⇒ Heating, air conditioning;
– Install centre console ⇒ General body repairs, interior; Rep.
sole .
– Install selector lever handle ⇒ page 45 .
– Adjust selector lever cable ⇒ page 59 .
– Check selector mechanism ⇒ page 58 .
– Install air filter housing ⇒ Rep. gr. 23 ; Air filter; Removing
and installing air filter housing . agen
AG. Volkswagen AG d
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olks not
Specified torques byV gu
ara
ed nte
ris
♦ Selector housing to body ⇒ page 43utho eo
ra
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ss
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3.5.2 Removing and installing selector mech‐

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pt
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anism without selector lever cable

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Brief description
wit
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In the interior, the centre console must be removed.

hole
spec
The heat shield beneath the vehicle must be removed.

es, in part or in w
t to the co
Removing
– Remove selector lever handle ⇒ page 45 .
rrectness of i
– Remove centre console ⇒ General body repairs, interior; Rep.

l purpos

sole .
nf
ercia
– If fitted, remove footwell air duct ⇒ Heating, air conditioning;

orm
m
atio
m

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n in
or c
thi
– Separate electrical connector from selector mechanism to ve‐

te
sd
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hicle wiring harness.

iv
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– Shift selector lever on selector mechanism to position “N”.

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– Install centre tunnel heat shield below selector mechanism ⇒

General body repairs, exterior; Rep. gr. 66 ; Mouldings/trims/
extensions; Removing and installing floor heat shield .
– 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 asAGshown

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– Remove securing clip -arrow-.

Always renew securing clip.
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– Pull selector lever cable out of selector mechanism.

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– Remove bracket -A- if present. agen oes
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cable must be checked for ease of movement and be adjusted.
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• Selector lever on selector mechanism must be set to position

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“N”.
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– Insert cable into selector mechanism, attach to selector lever
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and fit new securing clip.
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– Install centre console ⇒ General body repairs, interior; Rep.

sole .
– Install selector lever handle ⇒ page 45 .
Specified torques
♦ Selector housing to body ⇒ page 43
3.6 Removing and installing gear selector

cable

Removing
and installing air filter housing
– Unscrew bolts -2- for cable support bracket.
– Shift selector lever on selector mechanism to position “N”. On‐
ly in this position the selector lever cable can be released.
– Install centre tunnel heat shield olkbelow
swagen selector mechanism ⇒
General body repairs, wa en AG. V Rep.
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– Using a screwdriver lever the cover off from under the selector
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es, in part or in w
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– Release the cable as shown with a screwdriver, and pull off

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from the selector lever -arrows-.

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– Remove securing clip -arrow-. agen

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♦ Following installation, selector lever cable must be checked
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for ease of movement and be adjusted.
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• Selector lever on selector mechanism must be set to position

“N”.
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– Insert cable into selector mechanism, attach to selector lever
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and fit new securing clip.
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– Do not press ball head -1- of selector lever cable onto gearbox
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selector lever yet. Wait until selector lever cable has been
checked and adjusted.
– Check and adjust selector lever cable ⇒ page 59 .
and installing air filter housing .
Continue installation in reverse order of removal.
3.7 Checking selector mechanism

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

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

when the push-button is pressed. Solenoid for selector lever lock
blocks selector lever.
• Brake pedal is depressed:
Solenoid for selector lever lock releases selector lever. It is pos‐
sible to shift into a driving gear. Slowly shift selector lever from
“P” through to “S”, checking whether selector lever position in
dash panel insert corresponds to selector lever position.
Selector lever in “N” position and ignition switched on
• Brake pedal not depressed:
Selector lever is locked and cannot be shifted out of “N” position
with the push-button pressed. Solenoid for selector lever lock
blocks selector lever.
• Brake pedal is depressed:
Solenoid for selector lever lock releases selector lever. It is pos‐
sible to shift into a driving gear.
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• Shift selectoruthlever
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The illumination
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er must go out. “+” and “-” symbols must light up.

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When the selector lever is shifted into the Tiptronic gate, the se‐
erm
lector lever position display in the dash panel insert must change ab
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Ignition and light switched on
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Selector lever position indicator

Simultaneous illumination of all selector lever position display
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segments indicates gearbox emergency running mode.

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3.8 Checking and adjusting selector lever

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

Always adjust selector lever cable if the following applies:
♦ The selector lever cable has been removed from the gearbox.
♦ The engine and/or gearbox has been removed and installed.
♦ Parts of the assembly mounting have been removed and in‐
stalled.
♦ The cable itself or the selector mechanism has been removed
and installed.
♦ The position of the engine and gearbox is shifted, for example
to install it free of tension.
Check
• Air filter housing is removed. ⇒ Rep. gr. 23 ; Air filter; Re‐
moving and installing air filter housing
– Switch selector lever to “P” position.
olkswagen AG
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– Shift selector lever several times from position »P« toolk»S«
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• Selector lever must move easily. aut
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Adjusting
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– Move selector lever in vehicle to “P” position.

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– Selector shaft on gearbox is also in position “P”. To check,
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push lever opposite to driving direction to rear stop.
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Raise vehicle, to be sure that the gearbox is in “P” (parking lock
engaged). It should not be possible to turn both front wheels to‐
rrectness of i
gether in the same direction.
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– Loosen adjustment screw -arrow- for selector lever cable.

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– Gently push knob of selector lever forwards and backwards

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

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– Tighten bolt -arrow- to 15 Nm.

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– Install air filter housing.

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– ⇒ Rep. gr. 23 ; Air filter; Removing and installing air filter C py
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3.9 Renewing oil seal for selector shaft

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

♦ Tube - VW 423-
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♦ Extractor hook - T20143-
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♦ Not illustrated: Torque wrench - V.A.G 1331-

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Procedure
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• Gearbox is installed.
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• Renew bolts that are tightened with turning further angle after
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each removal.
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– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery .
– Unscrew bolt -arrow- and remove gearbox selector lever -1-.
cardiagn.com
– 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.
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– Fill half of the space between sealing lip and dust lip -arrow-
with sealing grease ⇒ Electronic parts catalogue . rrectness of i
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– Drive in seal to stop with tube - VW423- , being careful not to
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• Closed side of oil seal -arrow- faces towards outside.
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– Place gearbox selector lever -1- on shaft for parking lock and
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tighten bolt -arrow-.
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– Push selector lever onto gearbox selector lever, and adjust
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selector lever cable ⇒ page 59 .
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– Install battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
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Removing and installing battery tray .

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♦ ⇒ “3.1 Assembly overview - selector mechanism”, page 43 opyri
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4 Removing and installing gearbox

⇒ “4.1 Specified torques for gearbox”, page 64 agen
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⇒ “4.2 Removing gearbox”, page 65 d by ara
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⇒ “4.3 Install gearbox”, page 111 auth
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4.1 Specified torques for gearbox
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1, 2, 3 M12x55 80
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T10509:
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»65 Nm«
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4 M12x65 80
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5, 6, 7 M10x50 40
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8 M12×70 80
A Dowel sleeves for centring
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Component Specified torque

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Cable retainer to sump (gear‐ 10 Nm
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Earth lead to starter bolt 20 Nm
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Bevel box to gearbox
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Bevel box to gearbox ⇒ “2.1 Assembly overview - bevel
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♦ Renew bolts after re‐ box”, page 32 p by
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Gearbox carrier to engine and bevel box

Installation location and tightening sequence:
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

4.2 Removing gearbox

⇒ “4.2.1 Removing gearbox, Golf SV 2015 ►, Golf SV 2018 ►,
vehicles with diesel engine, front-wheel drive”, page 65
⇒ “4.2.2 Removing gearbox, Golf 2017 ►, Golf Estate 2017 ►,
vehicles with diesel engine, front-wheel drive”, page 77
⇒ “4.2.3 Removing gearbox, Golf 2017 ►, Golf Estate 2017 ►,
vehicles with diesel engine, all-wheel drive”, page 91
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⇒ “4.2.4 Removing gearbox, Golf 2017 ►, vehicles
ed
by with petrol en‐ ara
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4.2.1 Removing gearbox, Golf SV 2015 ►, ss c
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Golf SV 2018 ►, vehicles with diesel en‐
pt
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Brief description
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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
cardiagn.com
»from above«. Engine and gearbox must then be supported so
that left assembly mounting can be detached.
rrectness of i
»From below«
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Pendulum support and left drive shaft removed. Right drive shaft
remains installed in wheel bearing housing and only needs to be
nform
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swivelled to one side.

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The subframe remains in the vehicle.
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4. Removing and installing gearbox 65

Special tools and workshop

equipment required
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♦ Support - 10 - 222 A-
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♦ Adapter - 10 - 222 A /29- cted agen
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♦ 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-
♦ Hose clamps to 25 mm - 3094-
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♦ Tensioning strap - T10038-

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♦ Engine bung set - VAS 6122-

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♦ Release lever - 80 - 200-
♦ Insert tool, 18 mm - T10179-
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♦ Multi-point bit - T10061- olksw not
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♦ Adapter - 10 - 222 A /3-

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♦ Engine support - T50015A-
♦ Bracket - T10346/1-
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Removing
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– Switch selector lever to »P« position.

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After loosening centre bolt, do not lower vehicle to ground again.

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– Depress brake pedal to remove bolt for left drive shaft

-arrow- (second mechanic required).
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– Remove engine cover panel ⇒ Rep. gr. 10 ; Engine cover

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panel; Removing and installing engine cover panel .

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– 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 .
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– Remove bolts -arrows-
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– Open screw-type clip -3- and remove charge air pipe -1- ⇒
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Rep. gr. 21 ; Charge air system; Assembly overview - charge
erm
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air system .
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Disregard screw-type clip -2-.

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– Lever off selector lever cable -1- from gearbox selector lever
cial p
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using removal lever - 80 - 200- .

form
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– Unscrew bolts -2-, raise and tie cable support bracket -3- to‐
atio
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gether with selector lever cable.

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

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

escaping coolant.

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

and disconnect hoses from gear oil cooler.
– Release rotary fastener of connector for mechatronic unit -1- olkswagen AG

by turning in direction of starter and pull off connector. swagen AG. V does
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– Remove starter ⇒ Electrical system; Rep. gr. 27 d;bStarter;
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Removing and installing starter . tho
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– Remove charge air line. ⇒ Rep. gr. 21 ; Charge
ss air system;
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Assembly overview - charge air system

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– Unscrew upper engine/gearbox connecting bolts using insert
tool 18 mm - T10179- or insert tool 18 mm - T10509- .
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A bolt is located in the starter motor hole -arrow-. This bolt can be t. Cop py
removed using socket - T10061- .
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– If there are hose and cable connections in area of engine sup‐
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port eyes for support bracket - 10 - 222 A- , remove these now.
AG.
– 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).
♦ 2 x Adapter - 10 - 222 A /29-

– 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, agen
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– Remove lower part of front left wheel housing liner ⇒ General
rrectness of i
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; As‐
l purpos
sembly overview - front wheel housing liner .

Vehicles with window washer system:
nform
ercia
– Detach nut -3- from washer fluid reservoir -4- ⇒ Electrical

m
at
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system; Rep. gr. 92 ; Windscreen washer system; Removing
ion
c
and installing washer fluid reservoir .
in t
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ate
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-arrows-.

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– Detach connector -1- from oil level and oil temperature sender
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– Remove left drive shaft ⇒ Running gear, axles, steering; Rep.
mer
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gr. 40 ; Drive shaft; Removing and installing drive shafts .
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– 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.

– Remove clamp -2- for exhaust system from engine then raise
and tie front exhaust pipe ⇒ Rep. gr. 26 ; Exhaust pipes/
silencers; Assembly overview - silencer .
– 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.
cardiagn.com
– Remove bolts -arrows- of assembly mounting for gearbox.
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– Remove radiator cowl with radiator fan -arrow- ⇒ Rep. gr. 19 ; . Volkswage
Radiator, radiator fan; Removing and installing radiatorkscowl n AG
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left threaded hole for heat shield on engine block
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-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.
Gearbox support - 3282- is aligned with adjustment plate -

3282/61- for removal of gearbox 0GC.
– Gearbox support - 3282- is inserted in engine and gearbox
jack - VAS 6931- .
– Align arms of gearbox support with holes in adjustment plate .
– Screw support elements -A- into adjustment plate as illustra‐
ted. Deviating from this, pin - 3282/34- is used as rear right
support element. This support element is located outside ad‐
justment plate .
• Support element -C- on adjustment plate is not used.
– Position engine and gearbox jack - V.A.G 1383 A- with gear‐
box support - 3282- under gearbox.
All gearboxes are supported as shown in the illustration.

– 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.
olksw
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Transporting gearbox ⇒ page 117 .
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Secure gearbox to assembly stand ⇒ page 118 .
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Install gearbox ⇒ page 111 .
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4.2.2 Removing gearbox, Golf 2017 ►, Golf
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Brief description
nform
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The gearbox is removed downwards separately. The engine re‐

m
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Battery, battery carrier and air cleaner housing are removed

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The subframe remains in the vehicle.


equipment required
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♦ Adapter - 10 - 222 A /29- t. Cop py
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♦ Shackle - 10 - 222 A /12- Prote AG.
♦ Pin - 3282/29-

♦ Engine and gearbox

jack - VAS 6931-
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♦ Adjustment plate - ise d b ara
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♦ Hose clamps to 25
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♦ Tensioning strap -
AG.
T10038-

♦ Engine bung set -

VAS 6122-
♦ Insert tool, 18 mm -
T10179-
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♦ Multi-point bit - d by
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♦ Adapter - 10 - 222 A /
3-
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♦ Engine support -
T50015A-
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♦ Bracket - T10346/1-
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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 82 )
cardiagn.com
♦ or adapter -
T40093/3-6A- : qty. 2
Check adapters - AG. Volkswagen AG d
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T40093/3-6A- .
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At a later point, support

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

members with adapters -
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Removing
– Raise vehicle. All 4
supports of lifting
platform must be at
same height.
– Switch selector lever
to »P« position.
Note
After loosening centre

bolt, do not lower vehicle
to ground again.
– 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 .
cardiagn.com
locking mechanism -arrow- of battery olksw
tray -3-.
AG. V agen AG
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– Remove battery withVobattery
lksw tray ⇒ Electrical system;
es n
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gr. 27 ; Battery;seRemoving
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and installing battery trayu.aran
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Golf 2017 ➤rise, Golf Sportsvan 2015 ➤ , Golf Sportsvan
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7-speedaudual
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Note

open carefully.

escaping coolant.


– Release rotary fastener of connector for mechatronic unit -1-

by turning in direction of starter and pull off connector.
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
Removing and installing starter . olkswage es n
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A bolt is located in the starter motor hole -arrow-. This bolt can be
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– Remove fuel filter and lay to side. Do not open pipe/hose sys‐ C py
t. rig
tem ⇒ Rep. gr. 20 ; Fuel filter; Assembly overview - fuel filter .
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pyri by
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– If there are hose and cable connections in area of engine sup‐ cted agen
Prote AG.
Required material:
♦ Adapter - 10 - 222 A /3-
♦ 2 x Adapter - 10 - 222 A /29-
♦ Square tube - T40091/1-
♦ Connector - T40091/3-
♦ Spindle - T40093 /3-
♦ Check adapter - T40093/3-6- and modify as necessary
⇒ page 82
♦ or adapter - T40093/3-6A-


wing underneath it.

vehicle.
• Fit adapters - 10 - 222 A /29- directly onto the outer edge,

which faces towards wing -arrows-.
AG. gen AG Volkswa
The adapter on the “right” side of the vehicle agen
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– Slide adapter - 10 - 222 A /3- and joint - T40091/3- onto support
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bracket - 10-222 A- .
29- .
-A- = adapter - T40093/3-6A- (⇒ next figure) rrectness of i
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– If present, pull off wires in front area of flange on both longi‐

tudinal members -arrow-. Do not disconnect pipe/hose sys‐
tem.
– Place adapter - T40093/3-6A- onto 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 ; Refrigerant circuit;
System overview - refrigerant circuit . AG. Volkswagen
agen AG do
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– Bolt on spindle - T40093 /3- . y Vol ot g
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or
engine support bracket - 10-222 A- and
au fasten the connection ac
ss
(⇒ previous fig.).
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– Then attach spindles to engine support eyes.
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insulation .
t to the co
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body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; As‐
rrectness of i
sembly overview - front wheel housing liner .
l purpos
– Detach nut -3- from washer fluid reservoir -4- ⇒ Electrical
nf
ercia
o
system; Rep. gr. 92 ; Windscreen washer system; Removing
rm
m
and installing washer fluid reservoir .
atio
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n in
c
This will allow for pushing washer fluid reservoir aside slightly at
or
thi
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a later stage when removing the gearbox.

t
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2) Disregard bolts -1 and 2-.
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– Remove electrical wiring and retainers from sump at front

-arrows-.

– Release electrical connector for auxiliary hydraulic pump 1 for

– Detach connector -1- from oil level and oil temperature sender
- G266- , if fitted.
gr. 40 ; Drive shaft; Removing and installing drive shafts .
lkswage es n
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– If fitted, remove heat shield for right drive shaft -arrows- ⇒
wit
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Running gear, axles, steering; Rep. gr. 40 ; Drive shaft; Re‐
h re
hole
moving and installing drive shaft heat shield .
spec
es, in part or in w
– Remove right drive shaft from gearbox. ⇒ Running gear,
t to the co
axles, steering; Rep. gr. 40 ; Drive shaft; Removing and in‐
stalling drive shaft .
rrectness of i
l purpos
nform
mercia
at
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ion
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– Use tensioning strap - T10038- to secure drive shafts on sus‐

in t
or
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– Remove clamp -2- for exhaust system from engine then raise
and tie front exhaust pipe ⇒ Rep. gr. 26 ; Exhaust pipes/
silencers; Assembly overview - silencer .
– 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.
cardiagn.com
AG. Volkswagen AG d
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– Remove radiator cowl with radiator fan -arrow- ⇒ Rep. gr. 19 ;

Radiator, radiator fan; Removing and installing radiator cowl .
AG. Volkswagen AG d
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– Place protective mat between radiator and engine.

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– Secure bracket - T10346/1- to subframe as shown in illustra‐

mer
tion using an M 8 x 25 bolt -left arrow-.

atio
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n
c
– Screw engine support - T50015- to bracket - T10346/1- and to

i
or
n thi
left threaded hole for heat shield on engine block

te
sd
va
-right arrow-. To prevent damage to oil sump, insert a spacer

i
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-A- e.g. M12 nut between engine support and engine.

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– Force engine/gearbox as far forwards as possible by turning
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spindle of engine support - T50015- . Avoid collisions of com‐ ht. rig
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– Gearbox support - 3282- is inserted in engine and gearbox
jack - VAS 6931- .
– Align arms of gearbox support with holes in adjustment plate .
– Screw support elements -A- into adjustment plate as illustra‐
ted. Deviating from this, pin - 3282/34- is used as rear right
support element. This support element is located outside ad‐
justment plate .
• Support element -C- on adjustment plate is not used.
– Position engine and gearbox jack - V.A.G 1383 A- with gear‐
box support - 3282- under gearbox.
All gearboxes are supported as shown in the illustration.

– 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
cardiagn.com

4.2.3 Removing gearbox, Golf 2017 ►, Golf

gine, all-wheel drive
AG. Volkswagen AG d
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The gearbox is removed downwards
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»From above« aut
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The battery, air filter and starter are removed. The coolant hoses
ce
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must be clamped off. Support engine and gearbox before left

du
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subframe mounting is unbolted.

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»From below«
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The -subframe- is removed together with -pendulum support- and

h re
hole
-both suspension links-.

spec
es, in part or in w
Both drive shafts are disconnected from gearbox and left installed
t to the co
in wheel bearing housings. They are only swivelled to one side

and left on vehicle.
rrectness of i
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equipment required
cardiagn.com
AG. Volkswagen AG d
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or eo
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aut ra
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♦ Support - 10-222A-
h re
hole
spec
♦ Shackle - 10 - 222 A /12-

es, in part or in w
t to the co
♦ Support - 10 - 222 A /31-

♦ Engine support, basic set - T40091-
rrectness of i
♦ Engine support supplement set - T40093-

l purpos

nform
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ion
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cardiagn.com
AG. Volkswagen AG d
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or eo
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un
pt
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♦ Release lever - 80 - 200-

t to the co
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♦ Insert tool 18 mm - T10179- or insert tool AF 18 - T10509-
♦ Socket insert - T10061-
cardiagn.com
♦ Counter-hold tool - T10172A-
AG. Volkswagen AG d
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♦ Support bridge - T10323-

spec
es, in part or in w
t to the co
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♦ Adjustment plate - 3282/61-
Removing:
height.
Note
So that the propshaft can be turned later in order to loosen it:
cardiagn.com
– Move selector lever to »N« position.
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
agen oes
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ara
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pt
du
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ility
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es, in part or in w
t to the co
air system .
rrectness of i

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ion
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Prote AG.

Note

open carefully.
cardiagn.com
escaping coolant.
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– Clamp off coolant hoses using hoseVol
kclamps
swa to 25 mm - 3094-
oes
not
and disconnect hoses from gear
ed b oil cooler.
y gu
ara
is nte
or eo
– Seal connecting necks ofautgear
h oil cooler using suitable plugs ra
from engine bung set -sVAS 6122- .
s c
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nl
pt
du
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itte
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erm
ab
ility
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, is n
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es, in part or in w
t to the co

rrectness of i

l purpos

Removing and installing starter .
nform
ercia
It is advisable to remove the »lower« bolt first.

m
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ion
c
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or
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ate
do
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cum
for
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Cop py
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AG. Volkswagen AG d
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– Remove fuel filter and lay to side. Do not open pipe/hose sys‐
h re
hole
tem ⇒ Rep. gr. 20 ; Fuel filter; Assembly overview - fuel filter .
spec
es, in part or in w
t to the co
cardiagn.com
rrectness of i
Required material:
l purpos
♦ Adapter - 10 - 222 A /3-
nform
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com
tio
♦ 2 x Adapter - 10 - 222 A /29-
n in
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♦ Square tube - T40091/1-
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♦ Connector - T40091/3-
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♦ Spindle - T40093 /3-
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♦ Check adapter - T40093/3-6- and modify as necessary rig ht
py by
⇒ page 82
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♦ or adapter - T40093/3-6A-

wing underneath it.

vehicle.

• 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
recess of the wing.
– Slide adapter - 10 - 222 A /3- and joint - T40091/3- onto support

bracket - 10-222 A- .
29- .
-A- = adapter - T40093/3-6A- (⇒ next figure)
cardiagn.com
AG. Volkswagen AG d
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– If present, pull off wires in front area of flange on both
s longi‐
s a c
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un
pt
tem.
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– Place adapter - T40093/3-6A- onto right longitudinal member.
ab
pe
ility
ot
– If necessary, carefully unclip any pipes for air conditioning
wit
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hole

spec
System overview - refrigerant circuit .
es, in part or in w
t to the co
– Bolt on spindle - T40093 /3- .
– Connect spindle - T40093 /3- via square tube - T40091/1- to
rrectness of i
engine support bracket - 10-222 A- and fasten the connection

(⇒ previous fig.).
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– Then attach spindles to engine support eyes.

nform
ercia

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tion in

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Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐

thi
s
iva
sulation .
do
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body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; Re‐
Co
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moving and installing front wheel housing liner .
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rig by
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Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , sGolfwageSportsvan 2018 ➤
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– Remove electrical wiring and retainer from tho sump
frontauof or
ac
-arrows- (2 x M6 nuts). ss
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un
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ility
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t to the co
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– If fitted, pull connector -1- off oil level and oil temperature
ss
sender - G266- .
o
cial p
f in
– If fitted, pull connector off auxiliary pump for heating - V488-
form
mer
⇒ Rep. gr. 19 ; Coolant pump, thermostat; Assembly overview
atio
m
- electric coolant pump .

o
n
c
i
or
n
– Remove subframe ⇒ Running gear, axles, steering; Rep. gr.
thi
te
sd
a
40 ; Subframe; Removing and installing subframe without

iv
o
r
steering rack .
p
cardiagn.com
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ng
t.
yi Co
Cop py
t. rig
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pyri by
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by
cted agen
Prote AG.
– Remove drive shaft heat shield, if present, from bevel box ⇒
Running gear, axles, steering; Rep. gr. 40 ; Drive shafts; Re‐
moving and installing drive shafts .
Right drive shaft heat shield is secured with 2 or 3 nuts -arrows-.
– Detach left and right drive shafts from gearbox ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and
installing drive shaft .
– Secure both drive shafts on suspension strut with tensioning

belts - T10038- .

– Unscrew bolts -A- and -B-, and remove bevel box carrier -1-.
– Unscrew bolts -arrows- on bevel box, and remove heat shield

-1-.
cardiagn.com
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or
– Mark position of propshaft with flexible coupling relative
aut
h to eo
ra
output shaft of bevel box -arrows-. ss c
ce
le
un
pt
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d
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ility
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es, in part or in w
t to the co
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– Unbolt propshaft from bevel box -arrows- ⇒ Rep. gr. 39 ;

Propshaft; Removing and installing propshaft . nform
mercia
a
com
tion in
r
te o
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Prote AG.

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

tightening propshaft.
– Secure support - T10323- with a bolt on inside rear threaded

hole for subframe.
– A securing bolt from the subframe is suitable for this.
– Place cloth -A- on support and lay propshaft on that.
cardiagn.com
Note
♦ When removing and installing, do not damage seal in the

propshaft flange -arrow-.
AG. Volkswagen AG d
agen
♦ Renew propshaft if damaged.
Vol ⇒ Rep. gr. 39 ; Propshaft;otRe‐
es n o
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moving and installing spropshaft
ed
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♦ All parts of propshaft
au which have been marked relative to each
th or
ac
other must be reinstalled
ss in the same positions.
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wit
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Cop py
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py by
co Vo
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Prote AG.


-a-.
– Remove all connecting bolts except one which is in an easily
accessible place between engine and gearbox.
– An engine/gearbox connecting bolt -arrow- is located next to

bevel box -A-.
cardiagn.com
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Gearbox support - 3282- is aligned with adjustment plate s-s au ac
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– Move engine and gearbox jack under gearbox and support
itte
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gearbox. Do not raise.
erm
ab
ility
ot p
The gearbox is separated from the engine in this position.
wit
, is n
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– Remove last engine/gearbox connecting bolt.
hole
spec
– Press gearbox off engine while »observing selector lever ca‐
es, in part or in w
t to the co
ble«, and lower gearbox.
rrectness of i
l purpos
nf
ercia
4.2.4 Removing gearbox, Golf 2017 ►, vehi‐ orm

m
cles with petrol engine

atio
om
n in
or c
Brief description
thi
te
sd
iva
The gearbox is removed downwards separately.

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»From above«
t.
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The battery, air filter and starter are removed. The engine and
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gearbox must be supported before the left subframe mounting is p by
co Vo
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removed. Prote
cted AG.
agen
»From below«
-Subframe- is removed together with -pendulum support- and
-both suspension links-.
Both drive shafts are disconnected from gearbox and left installed
in wheel bearing housings. They are only swivelled to one side
and left on vehicle.


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
e
nl
pt
du
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ab
ility
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, is n
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es, in part or in w
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om
ion
c
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ate
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priv
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for
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t.
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pyri by
Vo
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by c lksw
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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-
cardiagn.com
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Prote AG.

♦ Release lever - 80 -
200-
♦ Insert tool 18 mm -
T10179- or insert tool
AF 18 - T10509-
cardiagn.com
♦ Socket insert -
T10061-
AG. Volkswagen AG d
agen oes
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♦ Square tube -
h re
T40091/1- , qty. 2
hole
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es, in part or in w
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r
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♦ Connecting piece -
s
iva
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T40091/3- , qty. 2
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Prote AG.

♦ Spindle - T40093 /3-

from engine support
supplementary set -
T40093- , qty. 2
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♦ Adapter -
pt
du
an
T40093/3-6- : qty. 2
itte
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erm
(check and modify as
ab
ility
necessary
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⇒ page 106 )
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t to the co
cardiagn.com
rrectness of i
l purpos
nform
ercia
♦ or adapter -
T40093/3-6A- : qty. 2
m
at
om
ion
♦ Adjustment plate -
c
in t
or
3282/61-
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
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co lksw
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cted agen
Prote AG.
Check adapters -
T40093/3-6- and modify
as necessary
– If necessary, cut off
the marked area.
– Round off front
edges.
– Protect adapter
against corrosion.
– Then, mark adapters
- T40093/3-6- as -
T40093/3-6A- .
At a later point, support
bracket - 10-222 A- will
be fitted onto longitudinal
members with adapters -
T40093/3-6A- .

• To prevent damage
to the longitudinal
members, wrap the
front section of the
adapters -
T40093/3-6A- with
textile-reinforced ad‐
hesive tape ⇒ Elec‐
tronic parts catalogue
(ETKA chemical sub‐
stances) .
Removing agen
AG. Volkswagen AG d
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– Raise vehicle. All 4 ed by
V gu
ara
supports of lifting horis nte
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platform must be at aut ra
c
same height. ss
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nl
pt
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– Move selector lever
an
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to position »P«.
erm
ab
ility
ot p
– Remove engine cov‐
wit
er panel ⇒ Rep. gr.
, is n
h re
10 ; Engine cover
hole
cardiagn.com
spec
panel; Removing and
es, in part or in w
installing engine cov‐
t to the co
er panel .
– Remove air filter
rrectness of i
housing ⇒ Rep. gr.
24 ; Air filter; Remov‐
l purpos
ing and installing air

filter housing
nf
ercia
– Remove battery and
orm
battery tray ⇒ Electri‐
m
atio
m
cal system; Rep. gr.

o
n in
c
27 ; Battery; Remov‐
or
thi
e
ing and installing bat‐

t
sd
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tery
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using removal lever - 80 - 200- . t. C rig
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pyri by
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agen
Prote AG.

– 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
agen oes
olksw not
y V gu
d b ara
ise nte
Golf 2017 ➤ , Golf Sportsvan
thor 2015 ➤ , Golf Sportsvan 2018 ➤ , Golf
e o Varia ...
u ra
7-speed dual clutch
ss a gearbox 0GC - Edition 01.2018 c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
– Seal connecting necks of gear oil cooler using suitable plugs
wit
from engine bung set - VAS 6122- .
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia

m
at
om
io
n
c
in t
or
Removing and installing starter .
his
ate
do
riv
It is advisable to remove the »lower« bolt first.

p
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for
en
ng
t.
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op py
cardiagn.com
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove all upper engine/gearbox connecting bolts.
port eyes for support bracket - 10-222A- , remove these now.
Required material:
♦ Adapter - 10 - 222 A /18-
♦ Shackle - 10 - 222 A /12- : qty 2 (required if spindles of support
bracket cannot be hooked into lifting eyes of engine).
♦ Adapter - 10 - 222 A /29- , qty. 2
♦ Square tube - T40091/1- , qty. 2
♦ Connecting piece - T40091/3- , qty. 2
♦ Spindles - T40093 /3- qty. 2
♦ Adapter - T40093/3-6- : qty. 2 (check and modify as necessary
⇒ page 82 )
♦ or adapter - T40093/3-6A- : qty. 2


wing underneath it.
“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- .
-A- = adapter - T40093/3-6A- (⇒ next figure)
cardiagn.com
– If present, pull off wires in front area of flange on both longi‐
tem. agen
AG. Volkswagen AG d
o
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olks o
– Place adapters by
V
- T40093/3-6A- onto both longitudinal
t gu
ara mem‐
ed
bers (illustration
h oris shows right longitudinal member). nte
e
t or
au a
– If necessary,
ss carefully unclip any pipes for air conditioning
c
ce
le
un
pt

an
d
itte
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System overview - refrigerant circuit .

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
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fo
en
ng
t.
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Cop py
ht. rig
rig ht
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109
cted agen
Prote AG.
4. Removing and installing gearbox
– Position adapter - T40093/3-6A- on left longitudinal memberAG. Volkswagen

directly behind filler pipe for washer fluid reservoir. lkswagen AG do
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the web of the longitudinal member -arrow-.
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– Screw in spindles - T40093 /3- .
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– Connect spindles - T40093 /3- via square tubes - T40091/1-
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to engine support bracket - 10-222 A- , and tighten (⇒ previous
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illustration).
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– Then attach spindles to engine support eyes. , is n
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Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
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– Remove electrical wiring and retainer from front of sump
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-arrows- (2 x M6 nuts).
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– Remove subframe ⇒ Running gear, axles, steering; Rep. gr.
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40 ; Subframe; Removing and installing subframe without
en
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t.
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steering rack . t. Cop py
rig
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Prote AG.
– Release electrical connector for auxiliary hydraulic pump 1 for

– 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- .

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– Remove all connecting bolts except one which is in an easily
hole
spec
accessible place between engine and gearbox.
es, in part or in w
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– Move engine and gearbox jack under gearbox and support
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gearbox. Do not raise.
in t
or
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ate
The gearbox is separated from the engine in this position.
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– Remove last engine/gearbox connecting bolt.

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– Press gearbox off engine while »observing selector lever ca‐ C py
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– Now slightly turn gearbox and lower it. Be sure to guide flange
-1- past intermediate plate -arrow- when lowering gearbox.
Note

4.3 Install gearbox

Install in the reverse order of removal, observing the following.

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– Renew needle bearing in crankshaft ⇒ Rep. gr. 13 ; Crank‐
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shaft; Renewing needle bearing in crankshaft .
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If the needle bearing in the crankshaft is damaged, the gears
t to the co
cannot be selected properly any more because the clutch is sup‐
ported on this bearing.
rrectness of i
– Lightly grease journal and splines on gearbox.
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– If there are no dowel sleeves -A- in the cylinder block for cen‐
tring the engine and gearbox, insert new dowel sleeves.
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• Missing dowel sleeves result in misalignment of the axes of
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It must be possible to guide the engine and gearbox together by C py
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ht. rig
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– 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 115
– If removed beforehand, install radiator cowl with radiator fan

-arrow- ⇒ Rep. gr. 19 ; Radiator, radiator fan; Removing and
installing radiator cowl .

– Reinstall nut -3- on washer fluid reservoir -4-. Specified torque:

⇒ Electrical system; Rep. gr. 92 ; Windscreen washer system;
Removing and installing washer fluid reservoir .
– Install pendulum support with new bolts. Specified torque: ⇒
cardiagn.com
Rep. gr. 10 ; Assembly mountings; Assembly overview - as‐
sembly mountings . gen AG
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– Install starter ⇒ Electrical
db
y V system; Rep. gr. 27 ; Starter;t gRe‐
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ua
moving and installing
or
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– Install drive shafts
ss
a ⇒ Running gear, axles, steering; Rep. gr. c
40 ; Drive shaft; Removing and installing drive shaft .
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nl
pt
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erm
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ility
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– If fitted, install heat shield for right drive shaft -arrows- ⇒ Run‐
es, in part or in w
t to the co
ning gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing

and installing drive shaft heat shield .
rrectness of i
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– Carefully remove strainer -1-edofbyoil cooler with a screwdriver ua
ran
and check for contamination.horis tee
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– Clean strainer if necessary
ss and clip back in place
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– Fit coolant hoses on gear oil cooler. du
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– Install wire retainer on sump.
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– Fit all electrical connectors on gearbox.
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es, in part or in w
– Install battery tray and battery ⇒ Electrical system; Rep. gr.
t to the co
27 ; Battery; Removing and installing battery .
rrectness of i
l purpos
– Check coolant level ⇒ Rep. gr. 19 ; Cooling system, coolant;

Draining and filling coolant .
nform
ercia
– Install lower part of front left wheel housing liner ⇒ General

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gr. 66 ; Noise insulation; Removing and installing noise insu‐

at
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lation .
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Specified torques: ⇒ page 64

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5 Assembly mountings
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⇒ “5.1 Assembly overview - assembly mountings”, page 115
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5.1 Assembly overview - assembly mountings
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spec
1 - Engine support
t to the co
❑ ⇒ Rep. gr. 10 ; Assem‐
bly mountings; Assem‐
rrectne
bly overview - assembly
mountings
ss
2 - Engine mounting
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cial p
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❑ ⇒ Rep. gr. 10 ; Assem‐
nform
bly mountings; Assem‐
mer
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bly overview - assembly
om
mountings
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3, 4, 5 - Bolt
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❑ Specified torque ⇒ Rep.
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❑ Version
7, 8, 9 - Bolt
gr. 10 ; Assembly
mountings; Assembly
overview - assembly
mountings
10 - Pendulum support
11 - Bolt
❑ For pendulum support
to subframe
gr. 10 ; Assembly
mountings; Assembly
overview - assembly
5. Assembly mountings 115

mountings
12 - Bolt
❑ For pendulum support to gearbox
❑ Renew after removal . Volkswagen AG
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❑ Gearbox with threaded insert ⇒ page ol swa
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❑ Specified torque ⇒ Rep. gr. 10
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13 - Bolt ss
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❑ For pendulum support to gearbox
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❑ Gearbox with threaded insert ⇒ page 116
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❑ Specified torque ⇒ Rep. gr. 10 ; Assembly mountings; Assembly overview - assembly mountings
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14 - Bolt
hole
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❑ For gearbox mounting to gearbox
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❑ Qty. 3
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❑ 60 Nm +90°
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15 - Bolt
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❑ Specified torque ⇒ Rep. gr. 10 ; Assembly mountings; Assembly overview - assembly mountings
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16 - Gearbox mounting
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Gearbox with threaded insert (e.g. “Heli-Coil”) for securing pen‐
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♦ There are threaded inserts, e.g. “Heli-Coil” in the bolting holes
for the pendulum support.
♦ Distinguishing feature: shoulder along beginning of thread
-arrow-.
♦ Note appropriate securing bolts and specified torque ⇒ Rep.
gr. 10 ; Assembly mountings; Assembly overview - assembly
mountings .

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♦ Gearbox mounting support - 3336-
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♦ 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-.
– Adjust support beam on sliding piece using locking pin

-arrow-.
• Number of visible holes (without bevel box) = 5.
• Number of visible holes (with bevel box) = 3.
– With gearbox lifting tackle - 3336- attached, take up weight of
gearbox using workshop hoist - VAS 6100- .
6. Transporting gearbox 117

7 Installing to engine and gearbox sup‐

port
♦ Retainer - VW 309- AG. Volkswagen AG d
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♦ or support plate - VW 309 d bA-
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♦ Gearbox support - VW 353-
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♦ Engine and gearbox support - VAS 6095A- cted agen
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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.

8 Gear oil circuit

⇒ “8.1 Assembly overview - gear oil circuit”, page 119
⇒ “8.2 Removing and installing gear oil cooler”, page 119
⇒ “8.3 Removing and installing gear oil filter”, page 122
⇒ “8.4 Removing and installing motor for auxiliary hydraulic pump
1 for gearbox oil V475 ”, page 123
8.1 Assembly overview - gear oil circuit
1 - Bleeder cap
2 - O-ring
❑ Renew
3 - Bolt
❑ 20 Nm
4 - Gear oil cooler
cardiagn.com
⇒ page 119
5 - Gearbox
⇒ page 64 AG. Volkswagen AG d
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7 - Motor for auxiliary hydraulic
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pump 1 for gearbox oil - V475-
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⇒ page 123
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8 - Seal
hole
spec
❑ Renew
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9 - Gear oil filter
❑ Information about oil
and filter change
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⇒ page 5
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⇒ page 122
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10 - O-ring
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❑ Lubricate with gear oil

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11 - Filter housing
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❑ 50 Nm
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12 - Heat insulation t. Cop py
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8.2 Removing and installing gear oil cooler
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8. Gear oil circuit 119

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– Move selector lever to position “P”.
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– If necessary, remove battery and battery tray ⇒ Electrical sys‐
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tem; Rep. gr. 27 ; Battery; Removing and installing battery
tray .
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open carefully.
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– Clamp off coolant hoses to gear oil cooler with hose clamps
-3094- and remove. Loosen hose clips -arrows- to do this.
– Seal open lines and unions with suitable plugs -1- from engine
bung set - VAS 6122- .
Caution
No coolant must be allowed to drip into gearbox!
– Cover gearbox with cloths to catch any escaping coolant.
– Unscrew bolts -arrows- and remove gear oil cooler -A-.

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Installing
Install in reverse order of removal, observing the following: rrectness of i
♦ Renew O-rings -arrows- after each removal.
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♦ Coat O-rings with gear oil to prevent pinching of rings during

assembly.
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♦ If sealing surface on gear oil cooler is damaged, it must be

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– Carefully remove strainer -1- of oil cooler with a screwdriver Cop py
and check for contamination.
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– Clean strainer if necessary and clip back in place.
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8. Gear oil circuit 121

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– Carefully bring gear oil cooler -A- into position. When
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– Tighten bolts -arrows- in stages and in diagonal sequence.
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– If removed, install battery and battery tray ⇒ Electrical system;
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– Check oil level and top up ⇒ page 127 .
– Check coolant level ⇒ Rep. gr. 19 ; Cooling system, coolant;
Draining and filling coolant .
rrectness of i
– Install noise insulation ⇒ General body repairs, exterior; Rep. l purpos
gr. 66 ; Noise insulation; Assembly overview - noise insula‐
tion .
nf
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Specified torques
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♦ Gear oil cooler to gearbox

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8.3 Removing and installing gear oil filter
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• There is normally no need to remove the gear oil filter. t. Cop py
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• Gear oil filter change “yes or no”: ⇒ page 5 . p by
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Special tools and workshop equipment required Prote AG.
♦ Used oil collector and extractor - VAS 6622A-
Removing
– Remove noise insulation -1- ⇒ General body repairs, exterior;
insulation .
– Remove battery and battery tray -1- -arrows- ⇒ Electrical sys‐
tem; Rep. gr. 27 ; Battery; Removing and installing battery .
– Place used oil collection and extraction unit - VAS 6622A- un‐
der gearbox.
TIP:
♦ A residual amount of gear oil remains in the oil filter. It runs out
when filter housing is unscrewed.
♦ Before unscrewing the filter housing, cover the area around
the gear oil filter with a sufficient number of cloths.
♦ Thoroughly clean oily areas on gearbox.

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

Renew missing or damaged heat insulation -1-.
Installing
• Renew O-ring after removal.
– Insert filter element -1- with intake collar -arrow- into gearbox.
– Tighten filter housing.
cardiagn.com
– Install battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Exploded view - battery .
gr. 66 ; Noise insulation; Assembly overview - noise insula‐
tion .
Specified torques
♦ Filter housing to gearbox
♦ Selector cable support bracket to gearbox wage
es n
⇒ “3.1 Assembly overview - selector mechanism”, page
yV
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8.4 Removing and installing motor for auxil‐ ss
au
th or
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♦ Puller - T10530-
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Removing
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Cop py
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8. Gear oil circuit
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– Release electrical connector for Volauxiliary hydraulic pump 1 for
not
gu
by
gearbox oil - V475- -a- and
ris
e pull off connector -b-.
d ara
nt ee
tho or
Vehicles with all-wheel sdrive:
au ac
s
ce
e
– Remove bevel box ⇒ page 33 . nl
pt
du
an
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– Remove bolts -arrows- (Shown on removed gearbox)
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– Insert puller - T10530- in hole. cop Vo
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– Turn knurled nut -2- clockwise until puller is fixed in position.
AG.
– Using puller - T10530- , carefully pull out pump motor to one

side horizontally.
Installing
– Renew seal
– Push pump motor evenly into housing by hand.
– Tighten pump motor.
Vehicles with all-wheel drive:
– Top up gear oil ⇒ page 130 , and check gear oil level
⇒ page 127 .
Specified torques
♦ ⇒ “8.1 Assembly overview - gear oil circuit”, page 119

9 Gear oil
⇒ “9.1 Overview of oil drain and inspection plugs”, page 125
⇒ “9.2 Tools for gear oil change”, page 125
⇒ “9.3 Checking gear oil level”, page 127
⇒ “9.4 Draining and filling gear oil”, page 130
9.1 Overview of oil drain and inspection plugs
1 - Overflow pipe
❑ 3 Nm
2 - Seal
❑ Renew
3 - Drain plug
❑ For gear oil
❑ 45 Nm
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4 - Drain plug for mechatronic
unit
❑ 10 Nm + 45°
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9.2 Tools for gear oil change

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9. Gear oil 125

♦ 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-
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♦ Genuine 1 litre oil bottle, dual clutch gearbox oil; part number
⇒ Electronic Parts Catalogue
♦ Vehicle diagnostic tester

♦ Safety glasses
♦ Acid-resistant protective gloves

Measure length of breather pipe attached to adapter for filling oil

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

pipe cutter -6056/2- .
– Clean adapter for filling oil - VAS 6262 A- .
cardiagn.com
9.3 Checking gear oil level
♦ ⇒ “9.2 Tools for gear oil change”, page 125
AG. Volkswagen AG d
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• Selector lever in position “P”.

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• The parking brake button has been pulled to activate the elec‐
h re
tromechanical parking brake.

hole
spec
• The extraction hoses of a switched-on exhaust extraction sys‐

es, in part or in w
t to the co
tem are connected.

• Engine running at idling speed.
rrectness of i
• Air conditioning system and heater switched off.

l purpos
Reading gear oil temperature

♦ The gear oil level changes depending on the gear oil temper‐
nf
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ature: if the gear oil temperature is too low, too much gear oil
rm
may be filled; if the gear oil temperature is too high, an insuf‐

m
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ficient amount of gear oil may be filled.

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♦ An improper gear oil level impairs the function of the gearbox.

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♦ At start of work, the oil temperature must not be above 30°C.

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If necessary, allow the gearbox to cool down.

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♦ Test temperature: 35 to 45°C.
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– Connect vehicle diagnostic tester -arrow- and identify vehicle
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9. Gear oil 127

– Select Dual clutch gearbox .

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

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

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

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

• If some gear oil still escapes at a gear oil temperature of be‐
tween 35 and 45°C (caused by the increasing temperature),
the gear oil level is OK.
• Irrespective of the gear oil level a small gush of oil escapes
cardiagn.com
from the overflow pipe every 30 seconds due to the cooling oil
pulses for supplying the multi-clutch. This is not relevant for
determining the gear oil level.
• Do not re-use gear oil which has escaped.
– If the gear oil level is OK, tighten the overflow pipe and com‐
plete the work sequence ⇒ page 130 .
Fill with gear oil
Caution
AG. Volkswagen AG d
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The correct oil level is below
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h the level of the overflow pipe.
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For this reason, the overflow pipe must be unscrewed 2 turns
s
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to enable the oil level to be checked and adjusted correctly.

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• The overflow pipe must be unscrewed by 2 turns.

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

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

es, in part or in w
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– Shake bottle before opening.

– Screw dual clutch gearbox oil bottle onto adapter for oil filling
- VAS 6262 A- .
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• If the thread of the bottle does not fit onto the oil filling adapter
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- VAS 6262 A- , use adapter - VAS 6262/6- .

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9. Gear oil 129

– Screw adapter for oil filling - VAS 6262 A- into inspection plug
opening hand-tight.
– Hold bottle with adapter for oil filling - VAS 6262 A- as high as
possible over the dual clutch gearbox, and allow the gear oil
to flow into the dual clutch gearbox.
– To check, if the dual clutch gearbox has been filled sufficiently,
disconnect the quick-release coupling on adapter for oil filling
- VAS 6262 A- at regular intervals, and seal the hose with your
finger or a clean plug.
• The accumulated gear oil flows out of the overflow pipe
-arrow 2-.
• Irrespective of the gear oil level there is always a slight amount
of gear oil which escapes.
• If some gear oil still escapes at a gear oil temperature of be‐
tween 35 and 45°C (caused by the increasing AG. Volkswagen AG d
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• Do not re-use gear oil which has escaped.
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spec
– If the gear oil level is OK, perform the required measures for
t to the co
completing the work sequence ⇒ page 130 .
Concluding measures
• Renew seal -arrow- for inspection plug. rrectness
– Unscrew adapter for oil filling - VAS 6262 A- from gearbox.

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– Tighten overflow pipe.

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– Tighten inspection plug -arrow-. cop Vo
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– Switch off ignition and separate diagnosis connections.
AG.
Specified torques
♦ ⇒ “9.1 Overview of oil drain and inspection plugs”, page 125
♦ Assembly overview - noise insulation ⇒ General body repairs,
exterior; Rep. gr. 66 ; Noise insulation; Assembly overview -
noise insulation .
9.4 Draining and filling gear oil

Procedure

♦ ⇒ “9.2 Tools for gear oil change”, page 125

Test conditions
• Gearbox not in emergency running mode.
• Selector lever in position “P”.
• The parking brake button has been pulled to activate the elec‐
tromechanical parking brake.
• Engine is not running.
Drain gear oil
insulation .
Caution AG. Volkswagen AG d

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Risk of injury to eyes and hands from
ised bescaping oil. ara
nte
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or eo
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• Wear protective goggles. s aut ra
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• Wear acid-resistant gloves
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low gearbox.
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– Unscrew inspection plug -arrow-.
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• The accumulated gear oil flows out of the overflow pipe.
t to the co
– Remove overflow pipe and allow gear oil to drain.
rrectness of i
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– Remove oil drain plug -arrow- from mechatronic unit.

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– Allow remaining oil to drain out.

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tighten.
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9. Gear oil 131

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.
cardiagn.com
– Screw adapter for oil filling - VAS 6262 A- into inspection plug
opening hand-tight.
– Hold bottle with adapter for oil filling - VAS 6262 A- as high as
possible over the dual clutch gearbox, and allow 6 l of gear oil
to flow into the dual clutch gearbox.
– Start engine and allow it to run at idling speed.
– Press brake and shift through all selector lever positions “P, AG. Volkswagen AG d
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– Switch selector lever to “P” position. utho or
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– Do NOT switch off engine.
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– Then, check oil level and top up as necessary ⇒ page 127 .

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Specified torques
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♦ ⇒ “9.1 Overview of oil drain and inspection plugs”, page 125

, is n
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hole
♦ Assembly overview - noise insulation ⇒ General body repairs,

spec
exterior; Rep. gr. 66 ; Noise insulation; Assembly overview -

es, in part or in w
t to the co
noise insulation .
rrectness of i
l purpos
nf
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m
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132
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35 – Gears, shafts
1 Currently, no repairs can be made to
gears and shafts
AG. Volkswagen AG d
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1. Currently, no repairs can be made to gears and shafts 133

39 – Final drive - differential d byV
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⇒ “1.1 Checking gear oil level”, page 134
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⇒ “1.2 Draining and filling gear oil”, page 134
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1.1 Checking gear oil level
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• The bevel box is bolted to side of the gearbox and has its own
spec
oil supply.
es, in part or in w
t to the co
• Specifications for gear oil ⇒ Electronic Parts Catalogue
Procedure
rrectness of i
• Renew bolt for oil filler hole after each removal.
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• Engine is not running.

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com
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insulation .
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– If necessary, unscrew nuts -arrows-, and detach heat shield
fo
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for right drive shaft.

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– Unscrew oil filler plug -1-.

• Specification: gear oil level to lower edge of filler hole.
– If necessary, top up gear oil ⇒ page 134 .
– 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 138
♦ ⇒ 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
134 Rep. gr.39 - Final drive - differential

♦ Adapter - VAS 6262/6- , if necessary
♦ Filling device for Haldex coupling 2 - VAS 6291 A-
cardiagn.com
AG. Volkswagen AG d
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♦ Adapter forautoil
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Prote AG.
1. Gear oil 135

♦ Genuine oil bottle, gear oil; part number ⇒ Electronic parts

catalogue
♦ Safety goggles
♦ Acid-resistant protective gloves
Draining
• Renew oil drain plug and bolt for oil filler hole after each re‐
moval.
AG. Volkswagen AG d
agen oes
• Vehicle is placed on a four-pillar lifting platform or above an y Volksw
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not
gu
assembly pit to ensure it is in total horizontal position. ised b ara
nte
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• Engine is not running. aut ra
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insulation .
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low gearbox.
h re
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– Unscrew oil drain plug -2-, and drain gear oil.
spec
es, in part or in w
t to the co
– Screw in new oil drain plug -2-.
rrectness of i
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nf
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m
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n in
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Replenishing
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– If necessary, unscrew nuts -1-, and detach heat shield for right
t.
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drive shaft. C py
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– Route hose of charging device for Haldex coupling 2 - VAS co Vo
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6291 A- through engine compartment. cted agen
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– 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 2 -
VAS 6291 A- with adapter for oil filling -VAS 6291/3- .
• Do not allow hose to sag.
cardiagn.com
– Ensure that valve -arrow- is closed. AG. Volkswagen AG d
agen oes
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– Screw oil reservoir -1- onto charging device forbyHaldex
Vol cou‐ not
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pling 2 - VAS 6291 A- . rised ara
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• In the case of some oil bottles, the adapter
ss a -VAS 6262/6- must ra
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be used as well.
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– Open valve -arrow-, and hold up oil container as shown in il‐
itte
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1. Gear oil 137

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• The bevel box will now be filled. au
th e or
ac
ss
• If bevel box has been properly filled, oil will emerge from
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adapter for oil filling -VAS 6291/3- .
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– If gear oil has emerged from adapter for oil filling - VAS
erm
ab
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6291/3- , position oil container so that surplus oil can run back
ot p
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into it.
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– When no more oil flows back, remove filling device for Haldex
spec
coupling 2 - VAS 6291 A- .
es, in part or in w
t to the co
– Screw in »old« oil drain plug and tighten slightly.
– Start engine, engage gear, and allow gearbox to turn for ap‐
rrectness of i
prox. 2 minutes.
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– Turn off engine and unscrew plug from oil filler hole.
– Check oil level, if necessary top up gear oil again to lower edge
nf
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of filler hole.
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– Tighten new oil filler plug.
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• Clean bevel box thoroughly to remove any remains of the
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emerged oil.
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rp
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– Install heat shield for drive shaft ⇒ Running gear, axles, steer‐
o
m
f
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ing; Rep. gr. 40 ; Drive shaft; Removing and installing heat

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shield for drive shaft . C py
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1- Oil filler plug
• Renew after removal
• 15 Nm
2- Oil drain plug

• Renew after removal
• 15 Nm
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐

tion; Assembly overview - noise insulation .

AG. Volkswagen AG d
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2 Oil seals
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⇒ “2.1 Overview of fitting locations - seals”, page thor 139 eo
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⇒ “2.2 Renewing left oil seal”, page 139 ss
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⇒ “2.3 Renewing right oil seal”, page 142
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2.1 Overview of fitting locations - seals
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1 - Seal, right
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❑ Renewing ⇒ page 142
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2 - Seal
❑ For selector shaft
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3 - Seal, left
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2.2 Renewing left oil seal

2. Oil seals 139

♦ Puller - T10055-
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♦ Drip tray for workshop hoist - VAS 6208-
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♦ 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.

– Grease drill bit -3- so that metal chips adhere to it.

– Seal drive shaft aperture on transmission with a clean cloth
-2-.
– Carefully drill a hole with a drill bit -3- (diameter 2 to 4 mm) into
outer sheet metal ring -1- of oil seal.
– Screw a self-tapping screw, approx. 4 mm in diameter, into

hole drilled in oil seal. Do not screw in sheet metal screw too
far to avoid damaging bearing behind it.
– Place drip tray for workshop hoist - VAS 6208- below gearbox.
– Pull out oil seal using puller - T10055- and adapter -
T10055/2- .
Make sure no metal chips get into gearbox and into opening for
cardiagn.com
drive shaft. Vacuum out metal chips first if necessary.
– Carefully remove cloths and make sure that no metal chips get
into gearbox.
– Carefully clean gearbox and opening for drive shaft.
If only the sheet metal ring could be pulled out, carefully lever out
rest of seal with a screwdriver.
Installing
the following:
AG. Volkswagen AG d
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Before installing the seal, apply sealing grease by for oil seal - G 052
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128 A1- to sealing lips and cavity, and apply
orise oil to outer circum‐ nte
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Installation position:
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Open side of oil seal faces gearbox.

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

rrectness of i
cant oil seal in the process.

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2. Oil seals 141

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– Lightly grease splines -arrow- on stub shaft with
ss moly lubricant
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- N 052 735 Y0- .
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– Install left drive shaft ⇒ Running gear, axles, steering; Rep.
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gr. 40 ; Drive shaft; Removing and installing drive shaft .
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2.3 Renewing right oil seal
nform
ercia
⇒ “2.3.1 Renewing right seal, vehicles with front-wheel drive”,

page 142
m
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ion
⇒ “2.3.2 Renewing right oil seal - all-wheel drive vehicles”,
c
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page 144
his
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2.3.1 Renewing right seal, vehicles with front-

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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

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

– Seal drive shaft aperture on gearbox with a clean cloth -2-.
– Using the 2 … 4 mm drill bit, carefully drill a hole into outer
sheet metal ring -1- of oil seal.
low gearbox.
– Screw a self-tapping screw, approx. 4 mm in diameter, into

hole drilled into oil seal.
cardiagn.com
– Pull out seal using puller - T10055- and adapter - T10055/2- .
– Carefully remove cloths. When doing this, make sure that no
metal chips get into gearbox.
– Carefully clean gearbox and opening for drive shaft.
AG. Volkswagen AG d
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inform
taking care not to cant oil seal.

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– Install right drive shaft ⇒ Running gear, axles, steering; Rep.

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gr. 40 ; Drive shaft; Removing and installing drive shaft .

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2. Oil seals 143

2.3.2 Renewing right oil seal - all-wheel drive

vehicles
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♦ Sealing grease - G 052 128 A1-

Procedure
– Remove bevel box ⇒ page 33 .
low gearbox.

– Lever out oil seal on dual clutch gearbox using extractor tool
- T20143/1- or - T20143/2- .
– Moisten new oil seal with gear oil along its outer circumfer‐
ence.
– Fill space between sealing lip and dust lip -arrow- with sealing
grease - G 052 128 A1- .
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2. Oil seals 145

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♦ Socket - T10107A-
Removing

– Unscrew nuts -arrows-, and remove heat shield for right drive
shaft.
low gearbox.
– Remove bolt for right flange shaft using socket - T10107 A- by
screwing 2 bolts into flange and counterholding flange shaft
with an assembly lever.
cardiagn.com
– Pull out flange shaft -1- using puller - T10037- .
-A- = M10 x 25 bolts
Note
Use puller - T10037- to remove the flange shaft to avoidolkdamage

to bearings of the flange shaft. swa
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– Carefully drive in flange shaft while turning it.

– Bolt on flange shaft.
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– Check gear oil level ⇒ page 134 .

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♦ Flange shaft bolt: 25 Nm

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♦ Drive shaft; Assembly overview - drive shaft ⇒ Running gear,

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axles, steering; Rep. gr. 40 ; Drive shaft; Assembly overview

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3. Differential 147
4 Components of bevel box

⇒ “4.1 Assembly overview - components of bevel box”,
page 148
⇒ “4.2 Renewing bevel box seals”, page 149
⇒ “4.4 Renewing left oil seal”, page 151
⇒ “4.5 Renewing needle bearing for right flange shaft”,
page 152
⇒ “4.6 Removing and installing output flange”, page 153
4.1 Assembly overview - components of bevel box
1 - Seal
❑ Between bevel box and
gearbox
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2 - Bevel box AG. Volkswagen AG d
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❑ 20 Nm
5 - Seal
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❑ For right flange shaft

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❑ To vent bevel box

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❑ Press in until stop is

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⇒ page 146
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9 - Seal
❑ Insert in annular groove
of right flange shaft.
❑ To renew, remove needle bearings (polygon bearings) -item 10-
10 - Needle bearing (polygon bearing)
11 - Retaining ring

12 - 12-point nut
❑ Secure new nut by peening ⇒ page 162
❑ 340 ±15 Nm
13 - Output flange
14 - Shim
❑ No replacement part
15 - Seal
❑ For bevel box output flange.
16 - Tapered roller bearing inner race
17 - Bolt
❑ 38 Nm
18 - Pinion housing
❑ With shaft bevel gear and tapered roller bearing outer race
cardiagn.com
❑ Carefully lever out on alternate sides
❑ Observe bolt holes; pinion housing fits in one position only
19 - O-ring
❑ To renew, unscrew bolts -item 17-, and carefully lever off pinion housing at recesses
❑ Do not remove 12-point nut -item 12- and output flange -item 13-
20 - Shim
❑ Observe bevel box bolt holes; shim fits in one position only
21 - Cap wage
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4.3 Renewing right oil seal

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♦ Comply with general notes ⇒ page 5 .

♦ Observe rules for cleanliness ⇒ page 5 .
rrectne
♦ Refer to general repair instructions ⇒ page 5 .

ss

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4. Components of bevel box 149

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♦ Sealing grease ⇒ Electronic parts catalogue
Procedure
• Gearbox is installed. n AG. Volkswagen AG do
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– Remove right flange shaft ⇒ page 146 . ir se
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– Pull out right oil seal using extractor hook -T20143/2-
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with sealing grease ⇒ Electronic parts catalogue .
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– Drive in new oil seal to stop using thrust piece - T10049- . Make
inform
sure to keep seal straight in the process.

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– Install right flange shaft ⇒ page 146 .

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4.4 Renewing left oil seal

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♦ Sealing grease ⇒ Electronic parts catalogue
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Procedure
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with sealing grease ⇒ Electronic parts catalogue .

– Drive in new oil seal to stop using thrust piece - T10298- . Make
sure to keep seal straight in the process.
4.5 Renewing needle bearing for right flange shaft

AG. Volkswagen AG d
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♦ Thrust plate - VW 401-

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

♦ Tensioning device - T10047-

Procedure
– Remove right flange shaft ⇒ page 146 .
– Fit assembly tool - T10047- as shown in illustration.
• Markings “B” on both parts of tool must face towards each
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– Remove retaining ring -A-.
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– Turn shaft -arrow- while pressing off to avoid damage to con‐
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mer
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– Turn shaft -arrow- while pressing off to avoid damage to con‐
om
n
tact surface of needle bearings on shaft.
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– Secure needle bearings with a new retaining ring.

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– Install right flange shaft ⇒ page 146 .

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4.6 Removing and installing output flange
4.6.1 Removing and installing output flange


equipment required
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♦ Support rails - VW 457-

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♦ Gearbox support - T10108- with stop plate - T10108/1-
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♦ Tapered roller bearing puller - V.A.G 1582-
♦ Grip tool - V.A.G 1582/13-
♦ Torque wrench - V.A.G 1601-
♦ Crankshaft seal installing tool - VW 204 B-

♦ Universal dial gauge holder - VW 387-
♦ Thrust plate - 40 - 105-
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♦ Socket, 34 mm - T50019- d by V gu
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♦ Dial gauge - VAS 6080- rrectness of i
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♦ Sealing grease ⇒ Electronic parts catalogue Prote AG.
♦ Bolt M10x30 (qty. 2)

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

Procedure
♦ There is a tapered roller bearing inner race pressed onto bevel
box output flange.
♦ This is removed later in the process.
♦ The tapered roller bearing for the bevel box output flange and
the shims are not to be renewed.
– Set bevel box on hole “arrow” in gearbox support - T10108-
marked with number -4-. To do so, place an M12x10 nut
-item A- between bevel box and gearbox support.
– Then, align bevel box with remaining 3 holes, and secure it
with nut -A- placed between bevel box and gearbox support.
AG. Volkswagen AG d
– Drain oil from bevel box ⇒ page 134 . lksw
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– Release peened points -arrows- of 12-point nut -A- from in‐
dentations of output flange -B- by driving them inwards.
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– Lock bevel box output flange with stop plate - T10108/1- by
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screwing in two M10 x 30 bolts -arrows-.
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A - Socket, 34 mm - T50019-
– Remove output flange nut.

– Swing bevel box so that output flange points upwards.

– Unscrew 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 bevelaggear.
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– Position output flange -A- evenly on support rails - VW 457-

inform
-arrows-.
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– Press shaft bevel gear off output flange -A-.

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– Press output flange -A- out of pinion housing.

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

remove output flange seal.
Caution AG. Volkswagen AG d

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V.A.G 1582/13- .
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• If tapered roller bearing inner race is damaged, bevel box
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– Place thrust plate - 40 - 105- on output flange.
hole
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– Using tapered roller bearing puller , pull tapered roller bearing
t to the co
inner race off output flange.
– Remove seal from output shaft.
rrectness of i
– Insert old tapered roller bearing inner race -1- into pinion hous‐
l purpos
ing.
– Lightly oil outer circumference of new seal -2- for output flange.
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– Press in oil seal flush.
AG.
• Make sure that larger diameter of -VW 204 B- points towards

oil seal.
– Fill half of space between sealing lip and dust lip with sealing
grease; sealing grease ⇒ Electronic parts catalogue .

– Press tapered roller bearing inner race ⇒ page 159 onto output
flange as far as it will go.
• Make sure that larger diameter of press tool -VW 454- points
towards output flange.
• Press on tapered roller bearing inner race as far as stop. Do
not expose the tapered roller bearing to higher forces than
necessary.
– Fit shim -2-, tapered roller bearing inner race -3- and pinion
housing -4- onto shaft bevel gear -1-.
• Reinstall old shim -2-. It assures bearing preload of shaft bevel
gear in pinion housing.
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– Carefully press pinion housing with output flange sas
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– Align old shim -3- with pinion housing -2-.

• Pinion housing -2- and shim -3- only fit in one position.
– Lightly moisten new O-ring -1- with gear oil and slide it onto
pinion housing -2-.
– Insert pinion housing -2- into final drive housing -4-.
Notes:
♦ Teeth of shaft and bevel gear must engage.
♦ Align holes for bolts of pinion housing with final drive housing.
– Tighten bolts -1- alternately and in small steps. Turn output
cardiagn.com
flange -2- slightly back and forth while doing so -arrows-.
– Tighten bolts -arrows- for pinion housing -A- diagonally and

alternately.
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– Tighten new 12-point nut for output flange.

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A - Socket, 34 mm - T50019-
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– in indentations (offset by 120°) of output flange -B- by peening AG. Volkswagen AG d
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♦ ⇒ “4.1 Assembly overview - components of bevel box”,
page 148

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Service

7-speed dual clutch gearbox 0GC

Service Department. Technical Information

All rights reserved.

Copyright © 2018 Volkswagen AG, Wolfsburg D4B806A4276

1.3 Notes on tow-starting/towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.4 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.5 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

6 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

3.1 Removing and installing right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

4 Components of bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

4.1 Assembly overview - components of bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

4.2 Renewing bevel box seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

4.3 Renewing right oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

4.4 Renewing left oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

4.5 Renewing needle bearing for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

00 – Technical data byV gu

while engine is running.

♦ Before working on vehicle with engine running, move se‐

trical and electronic components, observe the following:

To prevent damage to the electronic components when dis‐

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

1.2 Safety measures when working on ve‐

Injury hazard as a result of automatic engine start in vehicles

1.3 Notes on tow-starting/towing

Danger of irreparable damage to gearbox.

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

flat or the starter is not functioning.

1.4 Safety precautions when using testers

and measuring instruments during a

during a road test:

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

• Operation of test and measuring equipment while driving

2 Rep. gr.00 - Technical data

♦ Observe the necessary measures when disconnecting the

♦ Disconnect battery only after the ignition has been switch‐

– 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

has got into the oil.

♦ Seals and O-rings of the gearbox were renewed.

♦ The sump or mechatronic unit were renewed.

♦ The service interval was reached.

Filter must be changed if:

♦ 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- .

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