7 Speed Dual Clutch Gearbox 0gc Eng

Service
Workshop Manual
Karoq 2018 ➤ , Karoq 2020 ➤ ,
Kodiaq 2017 ➤ , Kodiaq 2019 ➤ ,
Octavia IV 2020 ➤ , Superb III 2015 ➤
7-speed dual-clutch gearbox 0GC
Edition 04.2020
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - differential
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.
Karoq 2018 ➤ , Karoq 2020 ➤ , Kodiaq 2017 ➤ , Kodiaq 2019 ➤ , Octavia ...
7-speed dual-clutch gearbox 0GC - Edition 04.2020
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when working on vehicles with start-stop system . . . . . . . . . . . . . . . . 1
1.2 Safety precautions during road tests in which testing and measuring equipment is used . . 1
1.3 Safety measures during towing/tow-starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Marking angle gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Rules of cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 General points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Seals and sealing rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.5 Screws, nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.6 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.1 Filling capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2 Allocation gearbox - engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.1 Fitting location summary - electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.1 Summary of components - Dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2 Removing and installing the clutch end cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.3 Remove double clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.4 Install double clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1 Mechatronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.1 Summary of components - mechatronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.2 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.3 Removing and installing mechatronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2 Angle gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.1 Summary of components - angle gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.2 Remove angle gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.3 Install angle gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3 Shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.1 Overview - shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.2 Summary of components - Gearshift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.3 Emergency release out of P position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.4 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.5 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.6 Inspecting the gearshift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.7 Removing and installing the selector lever control cable . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.8 Inspecting and adjusting the selector lever control cable . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.9 Installing the lock button at the selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.10 Replacing cable adjusting element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3.11 Replacing the sealing ring for the gearshift shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4 Removing and installing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4.1 Tightening torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Contents i
4.2 Removing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

4.3 Installing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
5 Assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
5.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
6 Transporting the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
7 Attachment at engine and gearbox mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
8 Transmission fluid circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
8.1 Summary of components - gear oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
8.2 Removing and installing gearbox oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
8.3 Removing and installing auxiliary hydraulic pump 1 for gear oil V475 . . . . . . . . . . . . . . . . 222
8.4 Remove and install the gear oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
9 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
9.1 Summary of components - oil drain plugs and check screws . . . . . . . . . . . . . . . . . . . . . . 226
9.2 Tools needed for changing the gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
9.3 Checking the gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
9.4 Draining and filling gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

1 Disassemble and assemble wheels and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

1 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
1.1 Checking the gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
1.2 Draining and filling gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
2 Sealing rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
2.1 Installation overview - sealing rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
2.2 Replacing left sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
2.3 Replacing right sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
3 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
3.1 Removing and installing right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
4 Bevel gear components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
4.1 Assembly overview - angle gearbox parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
4.2 Dismantling and assembling the bevel gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
4.3 Replacing gasket rings for angle gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
4.4 Replacing the right flange shaft needle bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
ii Contents
00 – Technical data
1 Safety instructions
(SRL001569; Edition 04.2020)
⇒ “1.1 Safety precautions when working on vehicles with start-
stop system”, page 1
⇒ “1.2 Safety precautions during road tests in which testing and
measuring equipment is used”, page 1
⇒ “1.3 Safety measures during towing/tow-starting”, page 1
⇒ “1.4 General safety instructions”, page 1
1.1 Safety precautions when working on ve‐

hicles with start-stop system
Injury hazard as a result of automatic engine start in vehicles with
start-stop system.
In vehicles with the start-stop system activated (identifiable by an
indication in the dash panel insert) the engine can start automat‐
ically if required.
– It is necessary to ensure that the start-stop system is deacti‐
vated when carrying out work on the vehicle (switch ignition
off and if required switch ignition on again).
1.2 Safety precautions during road tests in

which testing and measuring equipment
is used
There is an increased risk of injury or accident from unintended
motion and insufficient securing of testers and measuring instru‐
ments.
There is a risk of injury from the release of the passenger airbag
in the event of an accident.
Operation of test and measuring instruments by the driver while
driving may result in deviating from the direction of travel.
– Fasten test and measurement equipment with a strap on the
rear seat and secure their operation by another person sitting
on the rear seat.
1.3 Safety measures during towing/tow-

starting
Risk of damage to gearbox.
• When towing the vehicle, the selector lever must be in position
“N” and it must not be towed further than 50 km and faster than
50 km/h, otherwise the gearbox will be destroyed.
• It is not possible to tow start an engine, e.g. if the battery is
weak or the starter does not operate.
1.4 General safety instructions

Risk of accident and injuries when unintentionally engaging a
driving position while the engine is running.
• Before working on the engine when the engine is running,
push the selector lever in position “P” and apply handbrake.
1. Safety instructions 1
Risk of damage to the electronic components when disconnecting

the battery.
• Observe actions for disconnecting the battery ⇒ Electrical
system; Rep. gr. 27 ; Battery; Disconnecting and connecting
the battery .
• Disconnect and connect the measurement and test equipment
with the ignition off.
2 Rep. gr.00 - Technical data

2 Identification
⇒ “2.1 Gearbox identification”, page 3
⇒ “2.2 Marking angle gearbox”, page 4
2.1 Gearbox identification

The identification characters of the gearbox are on the top of the
gearbox near to the starter.
The gearbox identification characters are also printed on the

gearbox.
Example:
♦ PVQ = gearbox identification characters
♦ 28.09.14 = Production date
♦ Other production data
The gearbox identification characters also appear on the vehicle
data stickers.
2. Identification 3
2.2 Marking angle gearbox

Various types of the angle gearbox can be used on the vehicle.
Angle gearboxes can be distinguished as follows:
When the angle gearbox is installed, the identification can be
made by reading the recess in the area of the aggregate carrier
-arrow-.
The identification is located in the lower part of the angle gearbox

housing -arrow-.
If the gearbox is removed, it can be differentiated according to the
type of mounting of the output flange:

♦ The output flange of the “0CN” angle gear is fixed with a

twelve-point nut -A-, which is caulked -arrows-.
♦ The output flange of the angle “gear 0AV” is attached with a
hexagon nut -arrow-.
♦ The output flange of the angle gearbox “0FN” is fixed with a
lock washer -1-.
Overview of the angle gear, removing and installing
⇒ “2 Angle gearbox”, page 35 .
The angle gearboxes have a different oil filling quantity
⇒ “4.1 Filling capacity”, page 11
Bevel gear components
⇒ “4 Bevel gear components”, page 247
2. Identification 5
3 Repair instructions
⇒ “3.1 Rules of cleanliness”, page 6
⇒ “3.2 General points”, page 6
⇒ “3.3 General repair instructions”, page 7
⇒ “3.4 Seals and sealing rings”, page 10
⇒ “3.5 Screws, nuts”, page 10
⇒ “3.6 Contact corrosion”, page 10
3.1 Rules of cleanliness

♦ Thoroughly clean the connection points and their surroundings
before releasing.
♦ Seal the open lines and connections immediately with a clean
plug, e.g. from the plug set such as -VAS 6122- .
♦ Only install clean parts: remove spare parts from their wrap‐
ping immediately before fitting.
♦ Make sure no dirt gets into the gearbox when the gearbox is
open.
♦ Always replace paper gaskets after disassembly. Completely
remove old gaskets and thoroughly clean sealing surfaces.
♦ Place removed parts on a clean surface and cover them to
prevent them from getting dirty. Use sheeting and paper for
this purpose. Use lint-free cloths!
♦ Carefully cover or close opened components if the repair is not
completed immediately.
♦ Protect electrical plug connections from dirt and moisture and
only connect them when dry.
3.2 General points

Gearbox
The engine torque is transferred to the dual clutch via the fly‐
wheel.
The flywheel and the double clutch are interconnected via a ser‐
ration. Both together have the function of the two-mass flywheel.
The gearbox is installed as a manual gearbox. It is operated as
an automatic gearbox by means of alternate hydraulic actuation
of the dual clutches. This means that the gears are engaged au‐
tomatically or manually in Tiptronic mode. There is not clutch
pedal.
Shift mechanism
The selector lever position (setting the gearshift mechanism, if
required) is no longer transmitted mechanically to the transmis‐
sion via the selector cable.
The selector lever positions or change gear are transferred via a
separate control unit in the shift mechanism via the CAN databus
to the gearbox control unit.
Shifting is therefore performed without control cable. It is only in
selector lever position “P” that the parking lock engaged mechan‐
ically with the selector lever cable.

Changes of gear-change point on upward and downward gradi‐

ents
On upward or downward gradients, gear-changes are performed
automatically by additional shift characteristics depending on ac‐
celerator position and driving speed.
♦ On steep gradients, gear-change mapping is adapted to en‐
gine power output.
♦ On steep gradients, gear-change mapping is adapted to the
braking effect of the engine.
♦ By directly selecting a gear via the Tiptronic, it is also possible
to use engine braking by selecting a specific gear, e.g. when
driving on a slope during trailer operation.
3.3 General repair instructions

A number of general notes on the individual repair procedures,
which are valid for this particular workshop manual, are summar‐
ised here.
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 pro‐
cedures.
Targeted fault finding, Vehicle self-diagnosis and Measuring
method
• Before repairing the drive, try to determine the origin of the
damage as accurately as possible using the ⇒ Vehicle diag‐
nostic tester in the functions Targeted fault finding ,
Vehicle self-diagnosis and Measuring method .
Special tools
For a complete list of special tools used in this workshop manual,
see ⇒ Workshop equipment and special tools .
Gearbox
♦ Make sure no dirt gets into the gearbox when the gearbox is
open. This applies in particular if the dual clutch gearbox me‐
chatronics - J743- or oil pump for gearbox has been removed
or laid open, because any dirt entering can cause the gearbox
to fail.
♦ If the cover is unscrewed from the dual clutch gearbox me‐
chatronics - J743- or there is no oil in the gearbox, do not let
the engine run and do not tow the vehicle.
♦ Thoroughly clean the connection points and their surroundings
and then release.
♦ When installing the gearbox, ensure the dowel sleeves are
correctly located between the engine and gearbox.
Retaining elements
♦ Do not over-tension the circlips.
♦ Renew retaining rings which have been damaged or over‐
stretched.
♦ Circlips must be positioned in the base of the groove.
Oil for dual clutch gearbox
The dual clutch gearbox “0GC” only has 1 oil circuit.
This oil circuit is used for wheels and shafts, final drive, couplings
and the dual clutch gearbox mechatronics - J743- .
3. Repair instructions 7
The oil quality influences in a decisive way the function of the

gearbox.
NOTICE
Risk of damage to gearbox
– Only spare part gear oil should be used for the dual clutch
gearbox “0GC” ⇒ Electronic Catalogue of Original Parts .
Other gear oils lead to malfunctions and/or gearbox failure.
– An insufficient quantity and overfilling the oil also negatively
affects the function of the individual parts of the gear.
• For draining and filling or checking the gear oil level, which is
described in chapter
⇒ “9.2 Tools needed for changing the gear oil”, page 226 , use
the special tools indicated.
• Shake gearbox oil bottles well before opening to mix any sedi‐
ments at the bottom of the bottle with the oil.
• Do not mix any additives in the oil, also do not fill in other oil.
• Dispose of used oils properly.
• Drained oil must not be refilled.
Oil filter
The oil filter on the 0GC gearbox is not replaced as part of normal
maintenance.
The gear oil filter must only be replaced under the following con‐
ditions:
♦ Metallic swarf was found in the oil.
♦ The clutch is blown or mechanically damaged.
♦ Coolant has got into the oil.
After the following maintenance, the gearbox oil filter does not
need to be replaced.
♦ After replacing the gearbox oil cooler or sealing rings, provided
that no coolant has got into the oil.
♦ After replacing the sealing rings for gearboxes.
♦ After replacing the oil pan or mechatronics for dual clutch
transmissions - J743- .
Oil drain plugs and check screws
Summary of components
⇒ “9.1 Summary of components - oil drain plugs and check
screws”, page 226

Overflow pipe
The overflow tube -arrow- is behind the drain plug and check
screw for gear oil.
The overflow tube determines the oil level in the gearbox.
The overflow tube is made of plastic and has a 8 mm hex socket
for tightening.
Tightening torque
screws”, page 226 Pos. 1.
• You must observe the correct tightening torque for the over‐
flow tube, because you may break apart the thread and collar
if tightened excessively.
NOTICE
There are different versions of overflow pipe.
– Check which overflow pipe is installed and carry out the oil
level check right after the workshop process
⇒ “9.3 Checking the gear oil level”, page 227 .
• If the overflow tube has to be replaced, you must install an

overflow tube that is assigned to the gearbox ⇒ Electronic
Catalogue of Original Parts .
• Never install an overflow tube from another gearbox, because
this could cause the oil level in the gearbox to be incorrect!
Oil for angle gearbox
The angle gearbox has an automatic oil filling for final drives.
• Only spare part gear oil for final drives should be used for the
angle gearbox ⇒ Electronic Catalogue of Original Parts .
Other oils can lead to functional problems or to failure of the angle
gearbox.
Inspecting oil level in the angle gearbox
Draining and filling gear oil in the angle gearbox
⇒ “9.4 Draining and filling gearbox oil”, page 231 .
Electrical components
If you touch metallic objects, you will experience an electric shock
because of the electrostatic discharge from the body.
Static discharge from contact with electronic components of the
gearbox may cause the system to malfunction or fail.
• Do not touch plug contacts, connectors or »open« electric
components with your bare hands under any circumstances.
• Before working on the electrical/electronic components, touch
an earthed object, e.g. water pipe or lifting platform.
3. Repair instructions 9
3.4 Seals and sealing rings

♦ Always replace O-rings, sealing rings and gaskets after dis‐
assembly ⇒ Electronic Catalogue of Original Parts .
♦ After removing all seals, inspect the contact faces on housings
and shafts for burrs and damage and remove all which are
found.
♦ Radial shaft seals - before mounting lightly oil at outside di‐
ameter and fill half the space between the sealing lips
-arrow- with sealing grease - G 052 128 A1- .
♦ Install gasket rings with the open side towards the fluid to be
sealed.
♦ Before inserting the O-rings, coat with oil for the dual clutch
gearbox to prevent the rings being damaged during installa‐
tion.
♦ Inspect the gear oil after replacing the gaskets and gasket
rings, top up if necessary
3.5 Screws, nuts

♦ Slacken and tighten screws or fixing nuts of covers and hous‐
ings diagonally across in stages.
♦ Tightening torques are for unlubricated nuts, bolts and screws.
♦ Clean the thread of the screws that are inserted with a locking
agent with a wire brush. Insert bolts with locking agent - AMV
185 101 A1- .
♦ Clean all threaded holes into which bolts are screwed in with
locking agent, using a thread tap to remove old locking agent
residues. Otherwise there is a risk that the bolts will shear at
the next disassembling.
♦ Always replace self-locking screws and nuts after disassem‐
bly.
3.6 Contact corrosion

The gearbox housing and the clutch housing are made out of
magnesium alloy.
Bolts and other components that come into direct contact with the
gearbox have a surface with varying finishes in relation to it.
The use of substitute components causes contact corrosion
(screws. nuts. washers ...). The gearbox housing and clutch hous‐
ing are damaged.
Generally install parts which are indicated in the ⇒ Electronic
Catalogue of Original Parts .

4 Technical data
⇒ “4.1 Filling capacity”, page 11
⇒ “4.2 Allocation gearbox - engine”, page 11
4.1 Filling capacity

Filling quantity for the 0GC dual clutch gearbox
Filling capacity Dual clutch gearbox 0GC
Factory fill 7.2 l
Change in customer service approx. 6 - 6.5 l
Change interval ⇒ Maintenance ; Booklet Superb III Chapter “Inspection”
⇒ Maintenance ; Booklet Karoq Chapter “Inspection”
⇒ Maintenance ; Booklet Kodiaq Chapter “Inspection”
⇒ Maintenance ; Booklet Octavia IV Chapter “Inspection”
Gearbox oil specification Oil for dual clutch gearbox ⇒ Electronic Catalogue of Original Parts
Check transmission oil level and top up with transmission oil if

necessary ⇒ “9.3 Checking the gear oil level”, page 227 .
Draining and filling gearbox oil
Capacity angle gearbox
Filling capacity Angle gearboxes 0CN Angle gearboxes 0FN Angle gearboxes 0AV
New filling 860 ml 750 ml 890 ml
change volume approx. 720 ml approx. 600 ml approx. 750 ml
Top-up Filled for life, no top-up Filled for life, no top-up Filled for life, no top-up
Oil specification Oil for final drives ⇒ Elec‐ Oil for final drives ⇒ Elec‐ Oil for final drives ⇒ Elec‐
tronic Catalogue of Original tronic Catalogue of Original tronic Catalogue of Original
Parts Parts Parts
Checking the oil level

Drain and fill oil
4.2 Allocation gearbox - engine

⇒ “4.2.1 Assignment gearbox - engine, Superb III”, page 11
⇒ “4.2.2 Gearbox - engine assignment, Karoq”, page 12
⇒ “4.2.3 Assignment gearbox - engine, Kodiaq”, page 13
⇒ “4.2.4 Gearbox assignment - Engine, Octavia II”, page 14
4.2.1 Assignment gearbox - engine, Superb III

Vehicles with petrol engines, front-wheel drive
Front-wheel-drive
Vehicles with petrol Engine identification characters
engines
2.0 TFSI 140 KW TDL
4. Technical data 11

Front-wheel-drive
engines
UBA
Vehicles with petrol engines, four-wheel drive

All-wheel drive
engines
2.0 TFSI 200 KW TDF
UAN
Vehicles with diesel engines, front-wheel drive

Front-wheel-drive
Vehicles with diesel Engine identification characters
engine
2.0 l/110, 140 kW TDI SQM TDJ
CR SWV UAX
2.0 l/ 110 kW TDI CR TTC
(EA 288 evo) UEM
Vehicles with diesel engines, four-wheel drive

All-wheel drive
engines
2.0 l/140 kW TDI CR SQJ TCX
SWP UAH
4.2.2 Gearbox - engine assignment, Karoq

All-wheel drive
engines
1.5 TSI 110 KW SUH UAR
TDC
2.0 TFSI 140 KW TDD
UAL
Volkswagen Technical Site: http://vwts.ru http://vwts.info


All-wheel drive
engines
2.0 l/110 kW TDI CR SWT TDB
TNT UAU
2.0 l/140 kW TDI CR SWP TCX
TNU UAH
4.2.3 Assignment gearbox - engine, Kodiaq

Vehicles with petrol engines, front-wheel drive
Front-wheel-drive
engines
1.5 TSI 110 KW SWL
UBC

Front-wheel-drive
engine
2.0 l/110 kW TDI CR SUL
UAY

All-wheel drive
engines
1.5 TSI 110 KW SWK
UAS
2.0 TFSI 140 KW TDE
UAM

All-wheel drive
engines
2.0 l/110 kW TDI CR SUK
UAJ
4. Technical data 13
4.2.4 Gearbox assignment - Engine, Octavia II

Front-wheel-drive
engines
2.0 l/ 110 kW TDI CR TEZ
(EA 288 evo)

5 Electrical components
⇒ “5.1 Fitting location summary - electrical components”,
page 15
5.1 Fitting location summary - electrical components
1 - Mechatronics for double

clutch gearbox - J743-
❑ Summary of compo‐
nents
⇒ “1.1 Summary of com‐
ponents - mechatron‐
ics”, page 28
❑ Removing and installing
⇒ “1.3 Removing and in‐
stalling mechatronics”,
page 30
2 - Switch cover with gearshift
mechanism - EX2-
❑ For Octavia IV vehicles
❑ Overview
⇒ “3.2.3 Summary of
components - Gearshift
mechanism, Octavia
IV”, page 53
⇒ “3.4.4 Removing and
installing the cover with
operating element for
the gearshift mecha‐
nism - Octavia IV”, page
64
3 - Parking lock actuator -
V682-
❑ for Octavia IV vehicles
❑ with transmitter for park‐
ing lock - G474-
❑ Overview
⇒ “3.2.3 Summary of
components - Gearshift
mechanism, Octavia
IV”, page 53
❑ ⇒ “3.5.4 Removing and installing the gearshift mechanism with selector lever control cable, Octavia IV”,
page 76
4 - Selector lever - E313-
❑ with selector lever sensor control unit - J587- , selector lever lock solenoid - N110- and switch for selector
lever locked in P - F319-
❑ Components are permanently integrated in the shift mechanism and cannot be replaced separately
❑ check with ⇒ vehicle diagnosis tester
❑ Summary of components ⇒ “3.2 Summary of components - Gearshift mechanism”, page 49
❑ Removing and installing shift mechanism
⇒ “3.5 Removing and installing selector mechanism”, page 65
5 - 7-speed dual-clutch gearbox 0GC
5. Electrical components 15
30 – Clutch
1 Clutch
⇒ “1.1 Summary of components - Dual clutch”, page 16
⇒ “1.2 Removing and installing the clutch end cover”, page 16
⇒ “1.3 Remove double clutch”, page 19
⇒ “1.4 Install double clutch”, page 21
1.1 Summary of components - Dual clutch

Spare parts
1 - Circlip of dual clutch end

cover
❑ Replace after removal
2 - Circlip of dual clutch
3 - Circlip of driver disc
4 - Double clutch
❑ do not disassemble
❑ removing
⇒ “1.3 Remove double
clutch”, page 19
❑ installing
⇒ “1.4 Install double
clutch”, page 21
5 - Shims
❑ 10 adjusting washers of
various thicknesses are
graded by 0.05 mm
❑ Determine the thickness
of the adjusting washer
when installing the dual
clutch
⇒ “1.4 Install double
clutch”, page 21
6 - Clutch end cover
stalling the clutch end
cover”, page 16
1.2 Removing and installing the clutch end

cover
Special tools and workshop equipment required
♦ Assembly sleeve - T10459-
16 Rep. gr.30 - Clutch

Removing
– Drain out gear oil
– Removing the gearbox
⇒ “4.2 Removing the gearbox”, page 108 .
– Fasten the gearbox to the engine and gearbox holder
⇒ “7 Attachment at engine and gearbox mount”, page 218 and
turn it into the vertical position (coupling points upwards).
• Replace gearbox oil filter if necessary according to the follow‐
ing instructions ⇒ page 8 .
– Replace gearbox oil filter
⇒ “8.4 Remove and install the gear oil filter”, page 224 .
– Pry out and remove circlip of the clutch end cover -2- with the
screwdriver -1- in -direction of arrow-.
– Pry out and remove the clutch end cover -2- through the open‐
ing for the starter with screwdriver -1-.
• The dismantled clutch cover and circlip must not be reinstal‐
led; always use new components for the installation.
Installing
1. Clutch 17
• The clutch cover and circlip must always be replaced after

disassembly ⇒ Electronic Catalogue of Original Parts .
• Never install a new clutch cover with a hammer.
• Never touch the centre seal by hand or oil the seal! Seal is only
guaranteed if the thrust surface of the seal is completely free
of oil and dry.
• The clutch cover -A- can only be handled as shown in the il‐
lustration!
• If there are any stickers on the inside of the clutch cover, they
must be removed before installation.
• Clean and degrease assembly sleeve - T10459- before use.
• Do no use scratched or otherwise damaged sleeves.
• The contact surface on the end of the shaft -arrow- must be
free of oil and dry; if necessary, clean the contact surface.
Before installing a new cover, the middle seal must first be shaped
to the correct shape.
– Position the assembly sleeve - T10459- on an even surface.

– Slide on the clutch cover in -direction of arrow A-, as shown in

the figure.
• Slide the cover evenly to horizontal position.
– Pull the assembly sleeve - T10459- through the clutch cover
in direction of arrow -B- to bring the sealing lip to installation
position.
– Moisten outside cover seal with oil.
NOTICE
The clutch cover is not leak-tight.
If there are leaks in the area of the clutch cover, the gearbox
may be damaged as a result of loss of oil.
– Do not touch the seal in the inner opening of the clutch cover.
– Work with care when installing the clutch cover. Impact of
any kind will cause leaks.
– Fit the assembly sleeve - T10459- -B- to the shaft of the dual
clutch.
– Fit the clutch cover -A- in -direction of arrow- over the assem‐
bly sleeve - T10459- -B- and press evenly into installation
position.
It is possible to carefully lever the cover with a screwdriver -1- in

its position -arrow-, until the new circlip can be installed.
– Install new circlip.
• Only remove the assembly sleeve - T10459- after installing the
circlip.
– Installing the gearbox
⇒ “4.3 Installing the gearbox”, page 207 .
– Pour in gear oil
1.3 Remove double clutch

♦ Hook - 3438- 2 units
♦ Extractor tool - T10055-
♦ Retractor - T10525-
When installing the double clutch, its axial play is set. Therefore,
when removing and installing the clutch, the gearbox must be
fixed in a vertical position in the assembly stand (clutch pointing
upwards)
⇒ “7 Attachment at engine and gearbox mount”, page 218 . This
is the only way to correctly set the axial play of the clutch.
1. Clutch 19
Removing
– Remove the clutch end cover
⇒ “1.2 Removing and installing the clutch end cover”,
page 16 .
Important! Installation position of driver disc
– Check that the marking on the driver disc -arrow- closes flush
with the marking on the outer plate support.
If there is no marking:
– Mark the installation position of driver disc on the circumfer‐
ence of the outer plate support with waterproof felt-tip pen, as
shown.
• For installation, the driver disc must be returned to this posi‐
tion.
– Pry out the clutch cover circlip -2- with a screwdriver -1-.
Note
The circlip is replaced together with the clutch. If the removed

coupling is reinstalled, the circlip will also be reused.
– Fit the extractor to the serration, as shown, and carefully drive

the driver disc out of its seating in -direction of arrow-.
A - Extractor - T10525-
B - Extractor - T10055-
C - The gearbox is fixed in the assembly stand
⇒ “7 Attachment at engine and gearbox mount”, page 218 with
gearbox holder - T30109 (VW353)-

– Remove circlip -arrow- and keep it for later installation.

• Do not dispose of the circlip, as it is required to measure the
axial play.
– Remove adjusting washer -arrow-.

• Carefully remove the dual clutch.
• Make sure that the no part falls down, so never turn the clutch!
– Attach the hooks - 3438- to the 2 opposite points, as shown

-arrow-.
– Remove the dual clutch with hooks - 3438- -A-.
1.4 Install double clutch

♦ Universal dial gauge bracket - MP3-447 (VW 387)-
♦ Dial gauge
♦ Retaining bolt - T10524-
♦ Thrust piece - MP3-427 (40-21)-
1. Clutch 21
♦ Hook - 3438- 2 units

• The driver disc must stay locked between the serrations of the
outer plate support.
• If the driver disc is loosened, the plate clutches of the dual
clutch may slip out. The dual clutch might then be set up in‐
correctly when assembled, under certain circumstances.
• Do not remove the plate supports or even raise them slightly,
as the plates may be skewed.
– Already when taking the clutch out of the package press on
the clutch cover.
This should prevent that the clutch cover and the plate support
located underneath slip out of the inner plates.
Installing
– Turn the piston rings through one revolution by hand. They
must run freely and must not stick.
– Check that piston rings -1-, -2-, -3- and -4- are seated correctly.
• The joints -arrows- of rings -1- and -3- should line up over each
other.
• The joints -arrows- of rings -2- and -4- should be at an offset
of 180° to the joints of rings -1- and -3-.
Important! Installation position of driver disc
– Before installing, check that there is a marking on the dual

clutch -arrow-.
• If there is no marking, use a water-proof felt-tip pen to mark in
colour on the driver disc and outer plate support yourself.

– Fit the retaining bolt - T10524- -1-.

• A second mechanic should hold the retaining bolt - T10524-
-1- in place when the dual clutch is fitted.
– Carefully inset the dual clutch with the hooks - 3438- -A-.
• The dual clutch must not be allowed to fall. If necessary, it can
be fitted by rotating it slightly.
The dual clutch is in the correct installed position if the retaining

bolt - T10524- -A- has some slight play.
• The retaining bolt - T10524- -A- is kept in place until the clutch
end cover is installed.
• The dual clutch must not now be turned any further, as other‐
wise the retaining bolt - T10524- can be twisted out of its
position.
– Pry out the clutch cover circlip -2- with a screwdriver -1-.
• This circlip is reused.
1. Clutch 23
– Fit the extractor to the serration, as shown, and carefully drive

the driver disc out of its seating in -direction of arrow-.
A - Extractor - T10525-
B - Extractor - T10055-
C - The gearbox is fixed in the assembly stand
⇒ “7 Attachment at engine and gearbox mount”, page 218 with
gearbox holder - T30109 (VW353)-
• A second mechanic must hold the retaining bolt - T10524-
while driving out the disc.
– Carefully remove the driver disc from the dual clutch
-arrows- and place to one side.
• Do not remove the plate supports or even raise them slightly,
as the plates may be skewed.
Identifying adjusting washer for dual clutch
• The retaining bolt - T10524- is inserted at all times.
– Install the original circlip -arrow- temporarily (only for three

measurements).
First measurement (axial play of shaft)
– Screw the universal dial gauge holder - MP3-447 (VW 387)-
to the gearbox flange.
– Position the measuring tip of the dial gauge -A- on the input
shaft.
– Set the dial gauge to 0 with bias.

– Raise the dual clutch upwards to the stop with the hooks -
3438- -A- by pulling forcefully in -direction of arrow- and record
the result.
– Record this value as “A”.
• This value is used later for control measurement, so keep val‐
ue “A” until the last measurement.
Second measurement
– Position the measuring tip of the dial gauge -A- on the hub of
the large plate support.
• The measuring tip must not touch the circlip.
– Lift the dual clutch upwards up to the stop by pulling it forcefully
and record the result of measurement.
– Record this value as “B”.
Calculating and identifying the adjusting washer
The following formula is used for this calculation:
Measured value “B”
–
Measured value “A”
–
0.11
=
Thickness of the circlip to be installed
– Record result of measurement.
Shims are graded by 0.05 mm.
– Find the adjusting washer that is nearest the result.
• Always use the next larger adjusting washer – never install a
smaller adjusting washer.
Example:
Calculated size of the adjusting New adjusting washer
washer
1.28 mm 1.3 mm
1.26 mm 1.3 mm
1. Clutch 25
– Remove the old circlip -arrow-.

• Do not dispose of the circlip, as it will be used once more.
– Install the adjusting washer as applicable from calculation.

Control measurement
This is used to check the calculation and select the correct ad‐
justing washer.
– Install the original circlip -arrow-.

– Position the measuring tip of the dial gauge -A- on the hub of
the large plate support.
• The measuring tip must be in contact with the adjusting washer
-1-.
– Lift the dual clutch upwards up to the stop by pulling it forcefully
and record the result of measurement.
– Record this value as “C”.
Final calculation and deciding on which of the adjusting washers
will be installed
The following formula is used for this calculation:
Measured value “C”
–
Measured value “A”
=
Specified value
This specified value must be in the range of 0.05-0.12 mm.
If the specified value has not been reached, it must be achieved
by installing a thicker or thinner adjusting washer.
– Install the new circlip -arrow-.
– Insert the driver disc into the dual clutch.

• During installation, check that the marking on the driver disc
closes flush with the marking on the outer plate support
-arrows-.
• The second mechanic holds the retaining bolt - T10524- firmly
in position and presses it outwards slightly.
– Carefully drive the driver disc into its bearing with the drive
bushing - MP3-427 (40-21)- and plastic hammer.
– Install the circlip of the driver disc.
– Press the circlip at the break point clockwise into its final po‐
sition.
• The circlip must be completely locked in place.
– Use a screws to check that the circlip is seated correctly and
locked.
– Remove retaining bolt - T10524- .
– Install the clutch end cover
⇒ “1.2 Removing and installing the clutch end cover”,
page 16 .
1. Clutch 27
34 – Controls, housing
1 Mechatronics
⇒ “1.1 Summary of components - mechatronics”, page 28
⇒ “1.2 Removing and installing oil pan”, page 28
⇒ “1.3 Removing and installing mechatronics”, page 30
1.1 Summary of components - mechatronics
1 - Dual clutch gearbox 0GC

2 - Mechatronics for double
stalling mechatronics”,
page 30
❑ Pack and transport cor‐
rectly ⇒ page 31
❑ Correct routing
⇒ page 32
3 - Screw
❑ 9 pieces
❑ Mechatronics for double
on gearbox
❑ Tightening torque and
tightening order
⇒ page 33
4 - Sealing ring
❑ for plug of mechatronics
5 - Screw
❑ 4 pieces
❑ Cover of mechatronics
to gearbox
❑ 8 Nm + 60°
6 - Locking clip
❑ for plug of mechatronics
7 - Oil pan Volkswagen Technical Site: http://vwts.ru http://vwts.info
❑ with gasket
❑ Removing and installing ⇒ “1.2 Removing and installing oil pan”, page 28
1.2 Removing and installing oil pan

• Make sure no dirt gets into the gearbox when the gearbox is
open.
• Follow regulations for cleanliness when working on the gear‐
box; dirt when the dual clutch gearbox mechatronics - J743-
28 Rep. gr.34 - Controls, housing

is open in particular can lead to the failure of the gearbox

⇒ “3.1 Rules of cleanliness”, page 6 .
• Observe the general repair instructions
⇒ “3.3 General repair instructions”, page 7 .
NOTICE
– Do not run the engine or tow the vehicle when the oil pan
has been removed or without filling with gearbox oil.
Removing
– Shift selector lever into position “P”.
– With ignition switched off, disconnect battery earth strap ⇒
Electrical system; Rep. gr. 27 ; Battery; Disconnecting and
connecting battery .
– Remove the sound dampening system ⇒ General body re‐
pairs, exterior ; Rep. gr. 66 ; Noise insulation .
– Unscrew the nuts -arrows- and remove the bracket for electric
cables from the threaded bolts on the oil pan.
– Connect electric cables at the side in area of oil sump.
NOTICE
There is a risk of destruction of the dual clutch gearbox mecha‐
tronics - J743- .
Static discharges may destroy the control unit and the mecha‐
tronics.
– Do not in any circumstances allow the gearbox plug contacts
to come into contact with your hands.
– Grab with the hand (without gloves) at the mass, in order to

discharge yourself electrostatically.
– Unlock the cap of the connector by turning to the left in

-direction of arrow- and disconnect the connector from the
mechatronics.
– Position catch pan , e.g. -VAS 6208- , under the gearbox.
1. Mechatronics 29
– Remove locking clip -3-.

– Loosen screws -1- crosswise and remove.
– Remove oil sump -2- with the oil sump seal.
If necessary, release oil sump by applying light blows with a rub‐
ber-headed hammer.
Installing
Installation is carried out in the reverse order. When installing,
observe the following:
• Replace the oil sump, sump screws and securing clip after re‐
moval.
– Wet the gasket ring with gear oil.

When a new Mechatronics for dual-clutch transmissions - J743-
is fitted, it is fitted with a new O-ring.
– Remove oil and grease from sealing surface of gearbox hous‐
ing.
– Fit new oil sump for mechatronics with seal -2- and tighten the
new screws -1- crosswise in stages.
• Make sure that the electric cable is not pinched when fitting
the oil sump.
– Insert new locking clip -3-.
• The angled side of the locking clip points to the gearbox.
– Connect the plug of the dual clutch gearbox mechatronics -
J743- and lock the cap by turning it.
– Install the noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation .
Tightening torques and summaries of components
Note
Replace bolts / nuts that are tightened at an angle of rotation, as

well as replacement components after removal.
♦ Oil sump dual clutch gearbox mechatronics - J743- to gearbox

⇒ “1.1 Summary of components - mechatronics”, page 28
1.3 Removing and installing mechatronics

• Make sure no dirt gets into the gearbox when the gearbox is
open.
• Follow regulations for cleanliness when working on the gear‐
box; dirt when the dual clutch gearbox mechatronics - J743-
is open in particular can lead to the failure of the gearbox


⇒ “3 Repair instructions”, page 6 .
• If the gearbox is hot, the mechatronics may catch on the fitted
pins. In this case, you must leave the gearbox to cool.
NOTICE
– Do not run the engine or tow the vehicle when the oil pan
has been removed or without filling with gearbox oil.
Removing
– Removing the oil pan
⇒ “1.2 Removing and installing oil pan”, page 28 .
NOTICE
tronics - J743- .
tronics.
– Only then touch or remove them after you have discharged
yourself electrostatically at an earthed object beforehand,
e.g. skin contact with earth.
– Touch an earthed object with your bare hand (without
gloves) to discharge any electrostatic.
– Unscrew screws of the mechatronics -arrows- crosswise and

remove.
There is a risk of damage to the dual clutch gearbox mechatronics
- J743- .
1. Mechatronics 31
• Pack the mechatronics and only transport as follows.

– Carefully remove the mechatronics from the gearbox housing.
Correctly routing the dual clutch gearbox mechatronics - J743-
• The sensors -arrows- must point upwards when the mecha‐

tronics is transported.
Installing
• Remove oil and grease from sealing surface of gearbox hous‐
ing.
• Make sure no dirt gets into the inside.
• Pack the mechatronics and transport correctly ⇒ page 31 .
NOTICE
tronics - J743- .
tronics.
– Only then touch or remove them after you have discharged
yourself electrostatically at an earthed object beforehand,
e.g. skin contact with earth.
– Touch an earthed object with your bare hand (without
gloves) to discharge any electrostatic.

– Carefully insert the dual clutch gearbox mechatronics - J743-

-A- into the gearbox.
– Tighten new screws -arrows- hand-tight.
Tightening torque and tightening order
Step Screws Tightening torque

1. -1- to -9- 8 Nm
2. -1- to -9- Turn another 45°
– Installing the oil pan

⇒ “1.2 Removing and installing oil pan”, page 28 .
– After the installation of the new mechatronics, the basic setting
has to be done and the immobilizer has to be ⇒ Vehicle diag‐
nostic tester adapted.
1. Mechatronics 33
Note

♦ ⇒ “1.1 Summary of components - mechatronics”, page 28

2 Angle gearbox
⇒ “2.1 Summary of components - angle gearbox”, page 35
⇒ “2.2 Remove angle gearbox”, page 36
⇒ “2.3 Install angle gearbox”, page 43
2.1 Summary of components - angle gearbox
1 - Screw
❑ 25 Nm
2 - Protection plate
❑ for right drive shaft
3 - Screw
❑ Tightening torque ⇒
Chassis, axles, steer‐
ing; Rep. gr. 40 ; Drive
shaft; installing and re‐
moving the heat shield
for drive shaft
4 - Double screw
❑ 40 Nm
5 - Protection plate
❑ for propshaft
6 - Screw
❑ 20 Nm
7 - Angle gearbox
❑ Distinction and descrip‐
tion
⇒ “2.2 Marking angle
gearbox”, page 4
❑ removing
⇒ “2.2 Remove angle
gearbox”, page 36
❑ installing
⇒ “2.3 Install angle gear‐
box”, page 43
❑ Mounting overview of
angle gear
⇒ “4.1 Assembly over‐
view - angle gearbox
parts”, page 247
8 - Screw
❑ 4 pieces
❑ Tightening sequence ⇒ page 44
❑ 40 Nm + 90°
9 - Mounting bracket
❑ for angle gearbox
❑ Various designs, assignment ⇒ Electronic Catalogue of Original Parts
10 - Screw
❑ 40 Nm
2. Angle gearbox 35
11 - Screw
❑ 40 Nm
2.2 Remove angle gearbox

⇒ “2.2.1 Removing bevel gear, vehicles with 1.5 TSI petrol en‐
gine”, page 36
⇒ “2.2.2 Removing bevel gear, vehicles with 2.0 TFSI petrol en‐
gine”, page 38
⇒ “2.2.3 Removing the angle gearbox - vehicles with diesel en‐
gine”, page 40
2.2.1 Removing bevel gear, vehicles with 1.5

TSI petrol engine
♦ Insertion tool 8 mm - T40276-
♦ Socket - T10107A-
♦ Engine support bracket - T10533-
To remove the right-angle gear unit, the right-hand drive shaft
must be removed. With the vehicle still standing on its wheels,
therefore, the propeller shaft screw must be loosened -arrow-.
• If the vehicle is standing on the wheels, the cardan shaft bolt
can be released by a maximum of 90°, otherwise the wheel
bearing can be damaged.
– Loosen the right-hand cardan shaft -arrow- , ⇒ chassis, axles,
steering; Rep. gr. 40 ; Cardan shaft; Loosen the cardan shaft
screw connection and tighten .
– Shift selector lever to position “N”.
So that it is then possible to turn using the propshaft when loos‐
ening.
– Pull of the plug -arrow- from the oil level and oil temperature
sender - G266- .

– Unscrew screws -arrows- and remove heat shield for right

drive shaft ⇒ Chassis, axles, steering; Rep. gr. 40 ; Drive
shaft; Installing and removing heat shield for drive shaft (if
present).
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .
NOTICE
Risk of damage to the decoupling element of the exhaust sys‐
tem.
– The decoupling element in the pre-exhaust pipe should not
be stretched or bent by more than 10°.
– Loosen screw -2- and loosen clamping sleeve at connection

point of exhaust pre-venting pipe / turbocharger.
– Unscrew screw -1- and both nuts -arrows- and detach pre-
exhaust pipe with catalytic converter.
– Tie up the exhaust pipe.
– Remove propshaft from angle gearbox ⇒ Propeller shaft and
rear final drive; Rep. gr. 39 ; Propeller shaft; remove and install
propeller shaft .
– Screw engine support bracket - T10533- -A- to the screw hole

for front pendulum support and on the axle to the screw hole
for noise insulation.
– Rotate using the spindle of the engine support - T10533- -A-
in order to the engine/gearbox assembly forwards as far as
possible.
• When swivelling the engine/gearbox assembly, ensure that it
does not collide with the assemblies in the front part of the
engine compartment, in particular the fan shroud.
– Unscrew screws -A- and -B- and remove bracket for angle
gearbox.
2. Angle gearbox 37
– Tighten the screw on the right flange shaft with a socket insert
- T10107A- .
• To loosen the bolt, insert 2 bolts into the flange and counter‐
hold the flange shaft with am assembly lever.
Access to the top fixing screws between gearbox and angle gear‐
box is limited in some variants.
Layout of top fixing screws for angle gearbox -1- and -2- (screws
are partially covered by the angle gearbox).
♦ Screw -1- is located near to screw -A-.
♦ Screw -2- is located near to screw -B-.
♦ The pre-exhaust pipe with catalytic converter or particle filter
-C- is located above the screws.
– Unscrew the top fixing screws -1- and -2- for angle gearbox
with socket insert 8 mm - T40276- -D-.
– Unscrew the lower fixing screws -arrows- for angle gearbox.

– Carefully push off and remove the angle gearbox from the
clutch.
2.2.2 Removing bevel gear, vehicles with 2.0

TFSI petrol engine
♦ Tensioning strap - T10038-
ening.

– Lower assembly carrier into service position ⇒ Chassis, axles,

steering; Rep. gr. 40 ; Assembly carrier; Lowering the assem‐
bly carrier .
– Unscrew screws -arrows- and remove heat shield for right
drive shaft ⇒ Chassis, axles, steering; Rep. gr. 40 ; Drive
shaft; Installing and removing heat shield for drive shaft (if
present).
– Removing drive shaft right and left on the angle gearbox ⇒
Chassis, axles, steering; Rep. gr. 40 ; Cardan shaft; removing
and installing cardan shaft .
– Secure the drive shaft e.g. to the suspension struts with ten‐
sioning strap - T10038- .
propeller shaft .
gearbox -1-.
- T10107A- .
2. Angle gearbox 39
with socket insert 8 mm - T40276- -D-.

clutch.
2.2.3 Removing the angle gearbox - vehicles

with diesel engine
To remove the right-angle gear unit, the right-hand drive shaft
must be removed. With the vehicle still standing on its wheels,
therefore, the propeller shaft screw must be loosened -arrow-.
7
• If the vehicle is standing on the wheels, the cardan shaft bolt
can be released by a maximum of 90°, otherwise the wheel
bearing can be damaged.
– Loosen the right-hand cardan shaft -arrow- , ⇒ chassis, axles,
steering; Rep. gr. 40 ; Cardan shaft; Loosen the cardan shaft
screw connection and tighten .
ening.

– Separate electrical plug connection -1-.

– Unscrew screw -2-, detach heating backup pump - V488- and
push to side.
• Do not remove coolant hoses.
– Pull of the plug -arrow- from the oil level and oil temperature
sender - G266- .
– Unscrew nuts -arrows- and remove heat shield for right drive
shaft ⇒ Chassis, axles, steering; Rep. gr. 40 ; Drive shaft;
installing and removing heat shield for drive shaft (if present).
NOTICE
Risk of damage to the decoupling element of the exhaust sys‐
tem.
– The decoupling element in the pre-exhaust pipe should not
be stretched or bent by more than 10°.
– Unscrew screw -2- and remove clamping sleeve on pre-ex‐

haust pipe.
Do not unscrew screw -1-.
propeller shaft .
2. Angle gearbox 41
– Screw engine support bracket - T10533- -A- to the screw hole

for front pendulum support and on the axle to the screw hole
for noise insulation.
– Rotate using the spindle of the engine support - T10533- -A-
in order to the engine/gearbox assembly forwards as far as
possible.
• When swivelling the engine/gearbox assembly, ensure that it
does not collide with the assemblies in the front part of the
engine compartment, in particular the fan shroud.
gearbox.
- T10107A- .
with socket insert 8mm - T40276- -D-.


clutch.
2.3 Install angle gearbox

• Replace self-locking nuts and bolts each time they are re‐
moved.
• Lightly grease the teeth of the flanged shaft with spline grease.
– Insert new screws into the top fixing holes of the angle gearbox
before is it placed on the gearbox.
– Slide the angle gearbox onto the gearbox.
• Guide the teeth of the drive shaft for the angle gearbox in the
differential axis.
• If the grooves are set correctly, the angle gearbox engages on
the gearbox up to the stop.
NOTICE
Risk of damage to angle gearbox.
– Do not screw the angle gearbox to the gearbox with fixing
screws. If the angle gearbox is tilted, the fixing eyes may
break off.
– Tighten the fixing screws for top and bottom of angle gearbox.
• To tighten the upper screws -1- and -2- use the 8 mm insertion
tool - T40276- .
2. Angle gearbox 43
Tightening torques and tightening order of the angle gearbox

Step Screws Tightening torque / torquing angle
1. -Arrows- Tighten by hand as far as the stop
2. -Arrows- 40 Nm
3. -Arrows- Turn 90° further
– Insert right flange shaft screw and tighten with plug insert -
T10107A- .
• To tighten the bolt, insert 2 bolts into the flange and counter‐
hold the flange shaft on the assembly lever.
– Position bracket for angle gearbox and tighten.
Tightening torque and tightening order of the mounting bracket
for angle gearbox
The type of bracket may different, depending on engine - assign‐
ment ⇒ Electronic Catalogue of Original Parts

♦ Vehicles with 1.5 l TSI petrol engines

♦ Vehicles with 2.0 TFSI petrol engines
♦ Vehicles with 2.0 l TDI diesel engine
Step Screws Tightening torque

1. -A-, -B- Tighten by hand as far as the stop
2. -A- 40 Nm
3. -B- 40 Nm
Further installation occurs in reverse order to the removal.

– Fit propshaft to angle gearbox ⇒ Propshaft and rear final drive;
Rep. gr. 39 ; Propshaft; remove and install propshaft .
– Summary of components - installing right cardan shaft ⇒ Car‐
dan and rear final drive; Rep. gr. 39 ; Propshaft; Summary of
components - cardan shaft .
– Install heat shield for right drive shaft ⇒ Chassis, axles, steer‐
ing; Rep. gr. 40 ; Drive shaft; removing and installing heat
shield for drive shaft (if present).
Vehicles with 2.0 TFSI petrol engines
– Reinstalling subframe from service position ⇒ Suspension,
axles, steering; Rep. gr. 40 ; Unit carrier; Lowering subframe .
Continued for all vehicles
– Install the pendulum support ⇒ Rep. gr. 10 ; Assembly mount‐
ings; removing and installing the pendulum support .
– Fit the exhaust system to the engine (if removed) ⇒ Engine;
Rep. gr. 26 ; exhaust cleaning system; summary of compo‐
nents - exhaust cleaning .
Vehicles with diesel engine
2. Angle gearbox 45
– Install heating backup pump - V488- with a bolt -2- to engine

⇒ Rep. gr. 19 ; Coolant pump/regulation of cooling system;
Summary of components - electric coolant pump .
– Inspecting oil level in the angle gearbox
Note

♦ Summary of components - Angle gearbox

⇒ “2.1 Summary of components - angle gearbox”, page 35 .
♦ Summary of components - propshaft ⇒ Propshaft and rear
final drive; Rep. gr. 39 ; Propshaft; Summary of components
- propshaft .
♦ Summary of components - bottom track control arm, steering
joint ⇒ Chassis, axles, steering; Rep. gr. 40 ; Assembly car‐
rier; Summary of components - assembly carrier .

3 Shift mechanism
⇒ “3.1 Overview - shift mechanism”, page 47
⇒ “3.2 Summary of components - Gearshift mechanism”,
page 49
⇒ “3.3 Emergency release out of P position”, page 54
⇒ “3.4 Removing and installing selector lever handle”,
page 58
⇒ “3.5 Removing and installing selector mechanism”, page 65
⇒ “3.6 Inspecting the gearshift mechanism”, page 81
⇒ “3.7 Removing and installing the selector lever control cable”,
page 87
⇒ “3.8 Inspecting and adjusting the selector lever control cable”,
page 95
⇒ “3.9 Installing the lock button at the selector lever handle”, page
97
⇒ “3.10 Replacing cable adjusting element”, page 99
⇒ “3.11 Replacing the sealing ring for the gearshift shaft”,
page 101
3.1 Overview - shift mechanism
3. Shift mechanism 47
1 - Shift cover with control ele‐

ment for shift mechanism
64
❑ Perform emergency re‐
lease of gearshift
⇒ “3.3.3 Emergency re‐
lease out of P position,
Octavia IV”, page 55
2 - Centre console
⇒ general body repairs,
interior; Rep. gr. 68 ;
Centre console .
3 - Screw
❑ for attaching the upper
bracket for the centre
console to the lower part
❑ 8 Nm
4 - Upper bracket for the centre
console
5 - Air guide for the heater and
air conditioning system control
unit
❑ in centre console
6 - Nut
❑ 4 pieces
❑ for shift mechanism to
body
❑ 8 Nm
7 - Bracket for centre console
❑ with lock for emergency release cable
8 - Damping
❑ on the gearshift mechanism
❑ A cord for the emergency release cable is guided through the opening in the sound damper
9 - Shift housing
❑ Perform emergency release of gearshift
⇒ “3.3.3 Emergency release out of P position, Octavia IV”, page 55
⇒ “3.5.4 Removing and installing the gearshift mechanism with selector lever control cable, Octavia IV”,
page 76
10 - Heat shield
❑ Removing and installing ⇒ General body repairs, exterior; Rep. gr. 66 ; Sound damping .

3.2 Summary of components - Gearshift

mechanism
⇒ “3.2.1 Summary of components - Gearshift mechanism, Karoq,
Superb III”, page 49
⇒ “3.2.2 Summary of components - shift mechanism, Kodiaq”,
page 51
⇒ “3.2.3 Summary of components - Gearshift mechanism, Octa‐
via IV”, page 53
3.2.1 Summary of components - Gearshift mechanism, Karoq, Superb III
1 - Transmission cover with se‐

lector lever handle
stalling selector lever
handle”, page 58
❑ Emergency release out
of P position
⇒ “3.3 Emergency re‐
lease out of P position”,
page 54
❑ Bring the lock button on
the selector lever han‐
dle into installation posi‐
tion
⇒ “3.9 Installing the lock
button at the selector
lever handle”,
page 97
2 - Clamp
3 - Screw
❑ 4 pieces
❑ 4 Nm
4 - Shift mechanism
❑ with integrated selector
lever sensor control unit
- J587- with selector lev‐
er - E313- , with Tiptron‐
ic switch - F189- , with
selector lever switch
locked in P - F319- and
selector lever lock sole‐
noid - N110-
lease
⇒ “3.3 Emergency release out of P position”, page 54
❑ Removing and installing complete shift mechanism with selector lever control cable
⇒ “3.5.1 Removing and installing shift mechanism with selector lever control cable - Karoq, Kodiaq,
❑ Removing and installing shift mechanism without selector lever cable
⇒ “3.5.2 Removing and installing shift mechanism without selector lever control cable - Karoq, Superb III”,
page 69
❑ Check ⇒ “3.6 Inspecting the gearshift mechanism”, page 81
5 - Adjustment element for selector lever control cable
❑ Removing and installing ⇒ “3.10 Replacing cable adjusting element”, page 99
6 - Screw
❑ Adjusting screw for selector lever control cable
❑ 12 Nm
7 - Selector lever control cable
❑ Removing and installing ⇒ “3.7 Removing and installing the selector lever control cable”, page 87
❑ testing and adjusting ⇒ “3.8 Inspecting and adjusting the selector lever control cable”, page 95
8 - Lock washer
❑ To secure the selector lever cable
9 - Nut
❑ 4 pieces
❑ for shift mechanism to body
❑ 8 Nm
10 - Bearing bracket for gearshift mechanism
11 - Cover
12 - Screw
❑ Cable support bracket for selector lever control cable
❑ 20 Nm
13 - Retaining clip
❑ When removing, do not damage the selector lever control cable
❑ Fitting position: with the recessed side of the locking clip towards gearbox
14 - Cable support bracket for selector lever cable
15 - Grommet
❑ Attach into cable support
16 - Spacer
❑ Fitting position: the large ∅ points to the gearbox.
17 - Nut
18 - Screw
❑ 10 Nm + 90°
19 - Gearshift lever

3.2.2 Summary of components - shift mechanism, Kodiaq
1 - Transmission cover with se‐

lector lever handle
stalling selector lever
handle”, page 58
❑ Emergency release out
of P position
page 54
❑ Bring the lock button on
the selector lever han‐
dle into installation posi‐
tion
⇒ “3.9 Installing the lock
button at the selector
lever handle”,
page 97
2 - Clamp
3 - Shift mechanism
❑ with integrated selector
lever sensor control unit
- J587- with selector lev‐
er - E313- , with Tiptron‐
ic switch - F189- , with
selector lever switch
locked in P - F319- and
selector lever lock sole‐
noid - N110-
lease
page 54
complete shift mechanism with selector lever control cable
❑ Removing and installing shift mechanism without selector lever cable
⇒ “3.5.3 Removing and installing shift mechanism without selector lever cable, Kodiaq”, page 73
❑ Check ⇒ “3.6 Inspecting the gearshift mechanism”, page 81 .
4 - Screw
❑ 4 pieces
❑ 4 Nm
5 - Plug
6 - Nut
❑ 4 pieces
❑ for shift mechanism to body
❑ 8 Nm
7 - Screw
❑ 20 Nm
8 - Retaining clip
❑ When removing, do not damage the selector lever control cable
❑ Fitting position: with the recessed side of the locking clip towards gearbox
9 - Cable support bracket for selector lever cable
10 - Grommet
11 - Spacer
12 - Screw
❑ 10 Nm + 90°
13 - Nut
14 - Gearshift lever
16 - Screw
❑ Adjusting screw for selector lever control cable
❑ Inspecting and adjusting the selector lever control cable
⇒ “3.8 Inspecting and adjusting the selector lever control cable”, page 95
❑ 12 Nm
17 - Retaining clip
❑ Replace after disassembly
18 - Selector lever control cable
❑ Removing and installing ⇒ “3.7 Removing and installing the selector lever control cable”, page 87
❑ testing and adjusting ⇒ “3.8 Inspecting and adjusting the selector lever control cable”, page 95
❑ Check ⇒ “3.6 Inspecting the gearshift mechanism”, page 81 .

3.2.3 Summary of components - Gearshift mechanism, Octavia IV
1 - Shift cover with control ele‐

ment for shift mechanism
64
lease of gearshift
⇒ “3.3.3 Emergency re‐
lease out of P position,
Octavia IV”, page 55
2 - Air guide for the heater and
air conditioning system control
unit
❑ in centre console
3 - Nut
❑ 4 pieces
❑ for shift mechanism to
body
❑ 8 Nm
4 - Bracket for centre console
❑ with lock for emergency
release cable
5 - Damping
❑ on the gearshift mecha‐
nism
❑ A cord for the emergen‐
cy release cable is gui‐
ded through the opening
in the sound damper
6 - Shift housing
❑ Perform emergency release of gearshift
⇒ “3.3.3 Emergency release out of P position, Octavia IV”, page 55
⇒ “3.5.4 Removing and installing the gearshift mechanism with selector lever control cable, Octavia IV”,
page 76
7 - Upper bracket for the centre console
8 - Screw
❑ for attaching the upper bracket for the centre console to the lower part
❑ 8 Nm
9 - Screw
❑ 20 Nm
10 - Grommet
11 - Spacer

13 - Nut
14 - Screw
❑ 10 Nm + 90°
15 - Gearshift lever on the gearbox
3.3 Emergency release out of P position

⇒ “3.3.1 Emergency release from P position - Karoq, Superb III”,
page 54
⇒ “3.3.2 Emergency release out of P position, Kodiaq”,
page 54
⇒ “3.3.3 Emergency release out of P position, Octavia IV”,
page 55
3.3.1 Emergency release from P position -

Karoq, Superb III
– Removing the cover for the shift mechanism
page 58 .
– Lift the gearshift cover upwards over the handle.
– Depress the brake pedal or pull on the handbrake.
– Press the yellow plastic wedge in -direction of arrow- and hold
in this position.
The selector lever can now be shifted out of position »P«.
If the selector lever is then shifted again into the position “P”, it is
locked again in position “P”.
3.3.2 Emergency release out of P position,

Kodiaq
♦ Release tool - T30098-
– Depress the brake pedal or activate the handbrake.

– Fit the release tool - T30098- -1- in the -direction of arrow-

under the cover for shift mechanism and loosen the cover by
lifting it.
– Lift cover for shift mechanism upwards using the selector lever
handle.
– Press the yellow plastic lever in -direction of arrow- and hold

in this position.
The selector lever can now be shifted out of position »P«.
If the selector lever is then shifted again into the position “P”, it is
locked again in position “P”.
3.3.3 Emergency release out of P position,

Octavia IV
♦ Wedge - T10383/1-
♦ Rig pin - T10027A-
For emergency release of the »P«position, the cover with the
control element for shift mechanism must be released. The shift
cover must not be completely removed. It is sufficient to detach
them from the centre console and then lift them up.
• The plugs on the switch cover do not need to be disconnected.
• Depending on the type of repair, the vehicle must be properly
secured against unintentional rolling - permanent or temporary
emergency release.
Remove the shift cover

– Insert wedge - T10383/1- -A- between the shift cover and the
centre console, as shown in the illustration, and partially re‐
move the cover by lifting it up.
– Push the wedge underneath the shift cover into the area of
-Arrows B-, and release the cover from the locks by lifting.
– Raise cover for shift mechanism upwards.
The emergency release from the P position is carried out using

the control cable with handle -1-, which is located in the locks on
the left side of the centre console. The handle -1- is connected to
the P position emergency release fuse via the control cable.
The handle of the cable -1- is placed in the lock on the left side of
the centre console.
Permanent emergency release
If the battery is disconnected (de-energized), the parking lock is
permanently blocked and can only be released by an emergency
release.
– Pull on the cable handle -1- until it stops (approx. 40 mm) and
hold it briefly pulled out.
The parking lock is now permanently switched off and cannot be
mechanically blocked again. The parking lock can only be locked
by pressing the button »P« on the control element for shift mech‐
anism, and only after connecting the battery and after starting up
the electrical system.
Temporary emergency release with the option of reactivating the
parking lock
For a temporary release with the option to reactivate the parking
lock, use locking pin - T10027A- .

– Block the shift mechanism by inserting the locking pin -

T10027A- into the opening -A-.
– Pull on the cable handle -1- until it stops and hold in this po‐
sition.
The parking lock is now switched off.
– Press and hold lock button -B-.

– Release the emergency release cable (handle -1- previous
figure).
The lock button remains in the lower position.
The parking lock is now temporarily deactivated.
Activate the parking lock again
The emergency release can be released by repeatedly pulling the
control cable.
– Pull on the cable handle -1- until it stops and hold.

The lock button jumps back up when pulling the cable -1-.
By releasing the emergency release cable, it is pulled back into
the shift mechanism.
The parking lock is now activated again.
3.4 Removing and installing selector lever

handle
⇒ “3.4.1 Removing and installing selector lever handle -
⇒ “3.4.2 Removing and installing gearshift knob - Karoq”,
page 60
⇒ “3.4.3 Removing and installing selector lever handle - Kodiaq”,
page 63
⇒ “3.4.4 Removing and installing the cover with operating element
for the gearshift mechanism - Octavia IV”, page 64
3.4.1 Removing and installing selector lever

handle - Superb III
♦ Hose binding claw
Removing
– Fit the release tool - T30098- -1- in the -direction of arrow B-
lifting it in the -direction of arrow A-.
– Pull the cover upwards over the handle.
– Release plug connection -2-C from the lamp for selector lever
scale illumination - L101- and disconnect.
Do not pay attention to the position -1-.

– Open the warm-type clamp -arrow- below the handle.

• Replace the clamp after disassembly.
– Detach the selector lever handle -1- together with the selector
lever collar from the selector lever towards the top -arrow A-
so that the lock button -2- is not pressed in.
Note
Do not observe -arrow B-.
Installing
NOTICE
The shift mechanism can be damaged.
If the selector lever handle is installed with the lock button
pressed in, then the selector lever handle as well as the selector
lever control cable can be destroyed.
– In the installation position, the lock button on the selector
lever must not be pressed in and must protrude.
– If the lock button was inadvertently pressed in when remov‐
ing the selector lever handle, it must be repositioned
⇒ “3.9 Installing the lock button at the selector lever handle”,
page 97 .
– Press the selector lever handle -1- onto the selector lever in
-direction of arrow B- in such a way that the lock button -2- is
not touched.
• The selector lever handle must latch into the round slot of the
selector lever.
• The lock button -2- points in direction of travel.
• A new clamp is fitted to the handle.
– Tighten warm-type clamp -arrow- using the hose binding claw .

• The selector lever is only correctly secured when the gripper
clamp is under tension.
• Only then the lock button at the handle may be pressed.
The lock button can only show high resistance when it is pressed
on for the first time after installing the selector lever handle.
– Press lock button at selector lever handle.
– Install the cover for the selector lever.
– Inspect gearshift mechanism
⇒ “3.6 Inspecting the gearshift mechanism”, page 81 .
3.4.2 Removing and installing gearshift knob

- Karoq

Removing
– Push the unlocking tools - T30098- -2- into the gap between
the centre console and the switch cover in the
-direction of arrow B-.
• Fist, slide the unlocking tools - T30098- -2- into the gap in the
middle of the switch cover and then carefully push it into the
edges.
– With unlocking tools - T30098- -2-, carefully lever out the
switch cover from the centre console -arrow A-.

– Detach the selector lever handle -1- together with the selector
lever collar from the selector lever towards the top -arrow A-
so that the lock button -2- is not pressed in.
Note
Do not observe -arrow B-.
Installing
NOTICE
The shift mechanism can be damaged.
If the selector lever handle is installed with the lock button
pressed in, then the selector lever handle as well as the selector
lever control cable can be destroyed.
– In the installation position, the lock button on the selector
lever must not be pressed in and must protrude.
– If the lock button was inadvertently pressed in when remov‐
ing the selector lever handle, it must be repositioned
page 97 .
– Press the selector lever handle -1- onto the selector lever in
-direction of arrow B- in such a way that the lock button -2- is
not touched.
• The selector lever handle must latch into the round slot of the
selector lever.
• The lock button -2- points in direction of travel.
• A new clamp is fitted to the handle.

– Tighten warm-type clamp -arrow- using the hose binding claw .

• The selector lever is only correctly secured when the gripper
clamp is under tension.
• Only then the lock button at the handle may be pressed.
The lock button can only show high resistance when it is pressed
on for the first time after installing the selector lever handle.
– Press lock button at selector lever handle.
3.4.3 Removing and installing selector lever

handle - Kodiaq
depending on vehicle equipment, different types of selector lever
handles are used - assignment ⇒ Electronic Catalogue of Original
Parts .
Removing
– Depress the brake pedal or activate the handbrake.
– Fit the release tool - T30098- -1- in the -direction of arrow-
lifting it.
– Lift the gearshift cover upwards over the handle.

– Detach the handle together with the selector lever collar from
the selector lever towards the top so that the lock button is not
pressed in.
• The lock button must also not be pressed after removing, oth‐
erwise the selector lever handle cannot be installed.
Installing
• If the lock button was inadvertently pressed in when removing
the selector lever handle, it must be repositioned
page 97 .
– Slide the selector lever handle onto the selector lever up to the
stop with a new warm-type clamp.
• Do not secure the clamp yet.
– Press the button in the selector lever handle to test it.
If assembled incorrectly, the button will stay in the selector lever
handle and will not return to its original position.
• In this case, you must pull the handle off the selector lever,
return the button to its original position
page 97 and then install the handle again.
– Use the hose binding claw to secure the warm-type clamp to

the selector lever handle -arrow-.
3.4.4 Removing and installing the cover with

operating element for the gearshift
mechanism - Octavia IV
♦ Wedge - T10383/1-

Removing
– Insert wedge - T10383/1- -A- between the shift cover and the
centre console, as shown in the illustration, and partially re‐
move the cover by lifting it up.
– Insert the wedge underneath the shift cover into the area of
-Arrows B-, and release from the locks by lifting.
– Raise cover for shift mechanism upwards.
– Remove plugs -1-, -2-, -3- and -4- on the cover and control
element gearshift mechanism one after the other.
– Remove cover with control element for shift mechanism from
the centre console.
Installing
Installation is carried out in the reverse order.
3.5 Removing and installing selector mech‐

anism
⇒ “3.5.1 Removing and installing shift mechanism with selector
lever control cable - Karoq, Kodiaq, Superb III”, page 65
⇒ “3.5.2 Removing and installing shift mechanism without selec‐
tor lever control cable - Karoq, Superb III”, page 69
⇒ “3.5.3 Removing and installing shift mechanism without selec‐
tor lever cable, Kodiaq”, page 73
⇒ “3.5.4 Removing and installing the gearshift mechanism with
selector lever control cable, Octavia IV”, page 76
3.5.1 Removing and installing shift mecha‐

nism with selector lever control cable -
Karoq, Kodiaq, Superb III
♦ Unlocking tool -T10236-
Removing
– Remove handle for shift mechanism
page 58
– Remove centre console ⇒ Body assembly work inside; Rep.
gr. 68 ; centre console ,
– Remove the air guide in the centre console ⇒ Heating, air
conditioning; Rep. gr. 80 ; Overview of installation locations -
heating; Overview of installation locations - components in the
passenger compartment front .
– Disconnect plug connection for vehicle wiring harness to se‐

lector mechanism -1-.
Note
-Do not consider Pos. 2-.
– Remove air filter housing:

Petrol engines ⇒ Rep. gr. 24 ; Air filter; Removing and instal‐
ling air filter housing
Diesel engines ⇒ Rep. gr. 23 ; Air filter; Removing and in‐
stalling air filter housing
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery tray .
– Push ball socket -1- of selector lever control cable off the
gearshift lever with the unlocking tool - T10236- .
– Unscrew screws -2- of the cable support for selector lever
control cable and place to one side.
• Do not bend or buckle selector lever control cable.
For vehicles with front-wheel-drive

– Detach both underfloor trim panels -2- and -4- ⇒ General body
repairs - exterior; Rep. gr. 66 ; Underfloor trim panel .
• Detach underfloor trim panels by unscrewing the nuts on inner
side only (side at exhaust pipe).
– Removing tunnel cross-pieces (if present) -1- and -3- ⇒ Gen‐
eral body repairs, exterior; Rep. gr. 66 ; Underbody protection;
installing and removing tunnel cross-piece .
– Silencer -5- ⇒ Engine; Rep. gr. 26 ; Exhaust pipes/silencers .
For vehicles with four-wheel drive
– Remove the propshaft ⇒ Propeller shaft and rear final drive;
Rep. gr. 39 ; Propeller shaft; remove and install propeller shaft
– Remove the safety clamps -arrows- and heat shield for the
center tunnel underneath the shift mechanism -1- ⇒ General
body repairs, exterior; Rep. gr. 66 ; Sound damping .
• A second mechanic is needed under the vehicle to remove the
shift mechanism.
– Unscrew the nuts -arrows- in the vehicle interior.

– Remove the shift mechanism together with the selector lever
control cable downwards.
• While doing so, guide the selector lever cable out of the cable
support.
Installing
• Do not grease selector lever control cable.
• After installing the shift mechanism, check the selector lever
control cable is moving freely and adjust
⇒ “3.8 Inspecting and adjusting the selector lever control ca‐
ble”, page 95 .
– Install the heat shield underneath the gearshift mechanism ⇒
General body repairs, exterior; Rep. gr. 66 ; Sound damping .
– Install the propeller shaft ⇒ Propeller shaft and rear final drive ;
Rep. gr. 39 ; Propeller shaft; remove and install propeller
shaft .
– Install exhaust system and align free of stress ⇒ Engine; Rep.
gr. 26 ; Exhaust pipes/silencers .
– Install the tunnel cross-piece ⇒ External body repairs; Rep.
gr. 66 ; Underbody protection; install and remove tunnel cross-
piece .
– Install the underfloor trim panels ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Underfloor trim panel .
– Install the air duct element in the centre console ⇒ Heating
system, air conditioning system; Rep. gr. 80 ; Overview of
installation locations - heating system; Overview of installation
locations - components in the passenger compartment front .
– Install centre console ⇒ Body assembly work inside; Rep. gr.
68 ; centre console ,
– Installing the selector lever handle and cover for the shift
mechanism
page 58 .
– Setting selector lever control cable
ble”, page 95 .
– Install air filter housing:
– Install battery tray and battery ⇒ Electrical system; Rep. gr.

Note

♦ ⇒ “3.2 Summary of components - Gearshift mechanism”, page

49

nism without selector lever control cable
- Karoq, Superb III
Removing
– Remove handle for shift mechanism
page 58
– Remove the air guide in the centre console ⇒ Heating, air
conditioning; Rep. gr. 80 ; Overview of installation locations -
heating; Overview of installation locations - components in the
passenger compartment front .

Note
– Bring selector lever for the shift mechanism into position “N”.
• The catch can only be released and the selector lever cable
disconnected from the shift mechanism in this position.
– Remove tunnel cross-pieces -1- and -3- ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Underbody protection; installing
and removing tunnel cross-piece .
– Lift off with a screwdriver and remove cover at the bottom from
the shift mechanism -arrow-.
• Replace cover for shift mechanism after disassembly.

– Using a screwdriver, pull the shift cable from the shift lever in
the -direction of the arrow-.
– Remove the lock washer -arrow- and detach the selector lever
cable.
• Replace the lock washer after removing it.
– Pull the selector lever cable out of the shift mechanism.
– Unscrew screws -arrows- and remove the shift mechanism

upwards.
Installing
♦ Do not bend or buckle the selector lever control cable.
♦ Do not grease selector lever control cable.
♦ After installing the shift mechanism, check the selector lever
control cable for ease of movement and adjust
ble”, page 95 .
♦ The selector lever for the shift mechanism is at position “N”.
The selector lever control cable can only be locked in this po‐
sition.
– Insert selector lever cable into the shift mechanism, push onto
selector lever and secure with new lock washer.
– Close shift mechanism at the bottom with new cover.
shaft .
– Install rear silencer ⇒ Engine; Rep. gr. 26 ; Exhaust pipes/
silencers .
piece .
– Install both underfloor trim panels ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underfloor trim panel .
– Install the selector lever handle
page 58 .
ble”, page 95 .
Note


49


nism without selector lever cable, Ko‐
diaq
Removing
– Removing selector lever handle
page 58 .
– Remove the air guide in the centre console -1-.

Note
The control cable can only be detached in this position.
– Remove tunnel cross-pieces -1- and -3- ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Underbody protection; installing
and removing tunnel cross-piece .
– Detach the plug from the bottom part of the shift mechanism
and take off the lock washer for the selector lever cable
-arrow-.
– Turn the catch for the selector lever cable 90° in

-direction of arrow- with a large screwdriver.
– Pull the selector lever cable out of the shift mechanism.

– Unscrew screws -arrows- and remove the shift mechanism

upwards.
Installing
♦ Do not bend or buckle the selector lever control cable.
♦ Do not grease selector lever control cable.
♦ After installing the shift mechanism, check the selector lever
control cable for ease of movement and adjust
ble”, page 95 .
• The selector lever for the shift mechanism is at position “N”.
The selector lever control cable can only be locked in this po‐
sition.
– Insert the selector lever cable into the shift mechanism far
enough for it to be visible in the catch for the shift mechanism
-arrow-.

• The selector lever cable is secured once the recesses of the

catch are at right angles to the end of the cable.
– Install a new lock washer -arrow- and insert plug.

shaft .
piece .
– Install the selector lever handle
page 58 .
ble”, page 95 .
Note

♦ Shift mechanism to body

⇒ “3.2 Summary of components - Gearshift mechanism”, page
49
3.5.4 Removing and installing the gearshift

mechanism with selector lever control
cable, Octavia IV
• Before repair, the circuit must put in the “P” position.
– Switch into the “P” position by pressing the button.
Removing

– Press the actuator locking mechanism for the selector control

cable -3- in -Arrow direction A- until it stops and secure it by
turning it anti-clockwise in -Arrow direction B-.
– Remove the screws -1- for the selector lever control cable
support.
– Remove the selector lever cable -2- from the actuator -3- and
put it to one side.
• Do not bend or knick the selector lever control cable during
removal.
– Remove shift cover with control element for shift mechanism
⇒ “3.4.4 Removing and installing the cover with operating el‐
ement for the gearshift mechanism - Octavia IV”, page 64 .
– Screw out screws -2- and remove the bracket -1-.

– Remove the air guide in the centre console -3-.
– Remove screws -2- and take out tunnel bridge at the back
-1-.
• To remove the screws -2-, partially fold down the underbody
panels at the rear -3-.
– Remove silencer -5- (previous figure S34–10105) ⇒ Engine;
Rep. gr. 26 ; Exhaust pipes/silencers .
centre tunnel underneath the shift mechanism -1-.

• Screw tunnel bridge in front -1- onto the body with 2 screws to
prevent the shift mechanism from falling out. The shift mech‐
anism can be placed on the tunnel bridge after unscrewing the
fastening screws in the vehicle interior.
• Before removing the fastening nuts for the gearshift housing,
the emergency release control cable -2- must be detached
from the latches on the bracket of the centre console -3-.
• The detached emergency release control cable is connected
to the gearshift housing using a cord. The cable is guided
through the damping -1- when removing the gearshift mech‐
anism.
– Remove the nuts -arrows- in the vehicle interior.
After unscrewing the nuts -Arrows- the shift housing is released.
This can be placed on the tunnel bridge at the front. At the same
time, the bracket for the centre console -3- and the damping -1-
in the vehicle interior are detached.
– Remove the bracket for the centre console -3- and the damp‐
ing -1-.
– Disconnect the put connection -3- and lower the gearshift

mechanism with the emergency release control cable -2-.
– Remove the gearshift mechanism, and at the same time, guide
the selector lever cable with cable support out of the gearbox
area.
Installing
installation.
• After installing the gearshift mechanism, it must be adjusted
ble”, page 95 .
– Pull the control cable for shift mechanism under the vehicle
into the engine compartment, place the shift housing on the
front tunnel bridge, then pull it into the opening in the centre
tunnel and align it.
installation.
– Connect connector -3-.
– In the vehicle interior, insert the damping -1- into the gearshift
housing, and at the same time, pull through the emergency
release control cable -2-.
– Fit the brackets for the centre console -3- on the threaded bolts
for the gearshift housing, screw on the fastening nuts
-arrows- and tighten them crosswise one after the other.
– Insert the emergency release control cable -2- into the locks
on the left side of the bracket for the centre console -3-.
– Insert the air guide into the centre console -3-.

– Fit the top bracket for the centre console -1- and tighten the
screws -2-.
– Install shift cover with control element for shift mechanism
ement for the gearshift mechanism - Octavia IV”, page 64 .
piece .

– Fasten the control cable on the gearbox with screws -3-, at the
same time, push the end of the control cable into the actuator
lock -1-.
• The control cable actuator lock is in the pulled (locked) posi‐
tion, the cable end is inserted into the lock -1- and can move
freely.
ble”, page 95 .
– Install battery tray and battery ⇒ Electrical system; Rep. gr.
Note


49
3.6 Inspecting the gearshift mechanism

⇒ “3.6.1 Check shift mechanism Superb III, Kodiaq, Karoq”, page
81
⇒ “3.6.2 Check shift mechanism, Octavia IV”, page 85
3.6.1 Check shift mechanism Superb III, Ko‐

diaq, Karoq
Overview:
♦ Check the shift mechanism is working ⇒ page 81
♦ Check the ignition anti-removal lock is working ⇒ page 83
♦ Check locking bolt - vehicles with keyless locking and starting
system ⇒ page 83
♦ Check the lock button on the selector lever handle
⇒ page 83
♦ Checking the plug connections at the gearshift mechanism
⇒ page 84
Selector lever position indicator
If all parts of the selector lever position display are lit, it indicates
that the gearbox is in emergency operation mode.
Check that the shift mechanism is working
• In selector lever positions “S”, “D”, “R” and Tiptronic position
it must not be possible to activate the starter.
• At speeds above 5 km/h and shifting in selector lever position
“N”, the selector lever lock solenoid must not engage and block
the selector lever. Selector lever can be shifted in a driving

position.
• At speeds below 5 km/h (virtual standstill) and shifting in se‐
lector lever position “N”, the selector lever lock solenoid must
only engage after approx. 1 s. The selector lever can only be
moved from position “N” by activating the brake pedal.
Selector lever in “P”:
– Switch off ignition.
• The selector lever is locked and cannot be switched off with
the gearshift knob in the “P” position.
– Switch on the ignition.
• Brake pedal is not operated.
• The selector lever is locked when the button is pressed and
cannot be shifted out of position “P”. The selector lever lock
solenoid blocks the selector lever.
– Press brake pedal and hold.
• The selector lever lock solenoid releases the selector lever. It
is possible to engage a driving gear position.
– Slowly shift selector lever from “P” through “R, N, D, S”; while
doing so check whether the selector lever position in the dash
panel insert corresponds with the actual selector lever posi‐
tion.
Selector lever in position “N” and ignition switched on:

– Release brake pedal.
• The selector lever is locked and cannot be moved out of po‐
sition “N”. The selector lever lock solenoid blocks the selector
lever.
– Press brake pedal and hold.
• The selector lever lock solenoid releases the selector lever. It
is possible to engage a driving gear position.
Shifting out of the position “N” to “D” by activating the brake pedal
is also possible without pressing the button on the selector lever.
From position “N” to “R” the button on the selector lever also must
be pressed.
Selector lever in position “D” and ignition and light switched on:
• The selector lever is locked and cannot be shifted from posi‐
tion “D” to position “S”.
– Press the button on selector lever.
• The selector lever is released and can be shifted from position
“D” to position “S”.
Selector lever in position “D/S” and ignition switched on:

– Guide selector lever in the Tiptronic gear.
• The light for “D” on the l amp for selector lever scale illumina‐
tion - L101- must go out and the “+” and “–” symbols should
light up.
• When the selector lever is shifted to the Tiptronic gate, the
selector lever position indicator - Y6- in the dash panel insert
must change from “P R N D S” to “7 6 5 4 3 2 1”.

• The display of the selector lever position “7 6 5 4 3 2 1” in the

dash panel insert must indicate (change) a higher or a lower
gear when shifting the selector lever to “+” or to “–”.
If the gearshift mechanism does not function as described:
♦ Inspecting and adjusting the selector lever control cable
ble”, page 95
♦ Carry out targeted fault finding with ⇒ Vehicle diagnostic test‐
er.
Check the function of the ignition key removal lock
– Turn the ignition key slightly to the right (do not start the en‐
gine) in order to set the position “ignition on”.
– Depress brake pedal and hold pressed.
• Shifting the selector lever out of the position “P” when the lock
button is pressed at the selector lever handle must be possible
without jerking.
• The key cannot be withdrawn from the ignition starter switch
in any other selector lever position except in the position “P”.
– Withdraw ignition key.
• Only withdraw the key from the ignition starter switch if the
selector lever is in position “P”.
• The selector lever cannot be shifted out of position “P” when
the button is pressed and the brake pedal is actuated.
If the ignition key removal lock does not function as described:
er.
Check locking bolt - vehicles with keyless locking and starting
system
– Turn on the ignition by briefly pressing the button for the start‐
ing system - E378- .
• The warning labels must be displayed in the dash panel insert:
“The vehicle cannot be closed.”
– Switch on ignition and switch the selector lever to the “P” po‐
sition.
• The vehicle can be closed.
If the specified values are not reached:
er.
ble”, page 95
♦ Check lock button on selector lever handle.
Check lock button on selector lever handle
Check that the lock button is moving:
• The lock button must be able to be pressed without much ef‐

fort.
• The lock button must re-engage automatically and fully once
released.
♦ Check that the selector lever handle is correctly installed
page 58
♦ Check that the selector cable is not kinked.
Inspect proper operation:
• Ignition is switched on.
• The lock button on the selector lever handle must be pressed
for the following shifts.
• If the lock button is not pressed, the selector lever must not be
able to be pushed into the following positions.
♦ From the “P” position to “R” with a worn brake pedal.
♦ From the “N” position to “R”, at rest (standstill), after a long
wait, and with the brake pedal depressed.
♦ From “R” position to “P”.
♦ Check that the selector lever handle is correctly installed
page 58
♦ Check the plug connections for the gearshift mechanism.
♦ Check the magnet for the selector lever lock - N110- with gui‐
ded fault finding ⇒ Vehicle diagnostic tester.
ble”, page 95
Checking the plug connections at the gearshift mechanism
• Before repairing or checking the plug connections, try to de‐
termine the origin of the damage via the “targeted fault finding”
using the ⇒ Vehicle diagnostic tester.
• Before checking the plug connections, the event memory of
all control units in the vehicle must be queried, and any errors
must be eliminated.
– Check plug connections ⇒ Current flow diagrams, Electrical
fault finding and Fitting locations.
1- Plug connection for gearbox shift mechanism connecting
lines (with CAN bus line), to the selector lever lock magnet
- N110- and selector lever switch locked in P - F319-
2- Plug connection for selector lever position indicator - Y6-

3.6.2 Check shift mechanism, Octavia IV

WARNING
There is a risk of injury and vehicle damage.
When the engine is running, there is a risk that a gear may be
inadvertently engaged.
– Before working with the engine running, put the gearshift into
position »P« by pressing the button and activate the elec‐
tromechanical parking brake with the button.
– Observe safety measures when driving
⇒ “1 Safety instructions”, page 1 .
• To test the shift mechanism, all test points must be carried out
one after the other.
• If the target values are not reached, check the control element
for shift mechanism is correctly installed
ement for the gearshift mechanism - Octavia IV”, page 64 and
carry out guided troubleshooting with ⇒ Vehicle diagnostic
tester.
Overview of the tests to be carried out
♦ Check function of the »P« position button (activation of parking
lock) ⇒ page 85
♦ Inspect function of shift mechanism ⇒ page 86
♦ Check gear indicator ⇒ page 86
♦ Check display in dash panel insert ⇒ page 87
♦ Check parking lock ⇒ page 87
Check function of the »P« position button (activation of the park‐
ing lock)
Test step 1.1
• Ignition on, engine switched off, »P«position activated (inser‐
ted).
– Press the »P« position button, press the brake pedal.
– Push the control element for shift mechanism forward and re‐
lease.
Gear »N« must be engaged.
Gear »N« must be displayed on the dial range display - Y5- .
– Press »P« button.
»P«position must be activated.
Gear »P« is displayed on the dial range display - Y5- .
Test step 1.2
• Ignition on, engine running, gear »P« activated, brake pedal
is not operated.
– Push and release the control element for shift mechanism by
one or two positions back.
Gear »P« must remain engaged.
Test step 1.3
• Ignition on, engine running, gear »P« activated, brake pedal
is pressed.

Gear »D« is engaged.
Gear »D« is displayed on the dial range display - Y5- .
Gear »S« is engaged.
Gear »S« is displayed on the dial range display - Y5- .
– Push the control element for shift mechanism forward by one
position and release it.
Gear »N« is engaged.
Gear »N« is displayed on the dial range display - Y5- .
– Push the control element for shift mechanism forward by one
position and release it.
Gear »R« is engaged.
Gear »R« is displayed on the dial range display - Y5- .
Check that the shift mechanism is working
Test step 2.1
• Engine running, gear »D« activated, drive speed is faster than
4 km / h.
– Engage gear »N«.
Gear »N« is engaged.
– Engage gear »R«.
Not possible to engage gear »R«.
Gear »N« is constantly engaged.
– Engage gear »D« without using the brake pedal.
• The drive speed is higher than 4 km / h.
• It must be possible to engage.
Test step 2.2
• Engine running, gear »D«, »R« or »N« engaged, drive speed
is 0 km / h.
– Engage gear »P«.
Gear »P« is displayed on the dial range display - Y5- .
Check gear indicator
Test step 3.1
• Engine running
– Engage gears »P«, »R«, »N«, »D / S« one after the other.
• The currently selected gear must light up more clearly and with
a different colour (yellow) compared to other gear symbols.
Test step 3.2
• Engine running
– Engage gear »P«.
• Symbol »P« on the button must light up in yellow.

All other gears must not light up yellow, they only light up in the
white base colour.
Check display in dash panel insert
Test step 4.1
• Engine running, gear »P« engaged, brake pedal is not press‐
ed.
– Engage gear »D« or »R«.
• The following message must appear in the dash panel insert:
“If you want to engage a gear, press the brake pedal and the
selector lever.”
Check parking lock
Test step 5.1
• Engine running, gear »D«, »S« or »R«, vehicle standstill
– Switch off engine.
• Gear »P« must be engaged automatically.
Test step 5.2
• Engine running, gear »N«, vehicle standstill
– Switch off the engine and open the driver's door.
• The following message must appear in the dash panel insert:
“Engage P-position before getting out, otherwise the vehicle
can roll off.”
• An acoustic signal must also sound.
3.7 Removing and installing the selector

lever control cable
⇒ “3.7.1 Removing and installing the selector lever control cable,
Karoq, Superb III”, page 87
⇒ “3.7.2 Removing and installing the selector lever control cable
- Kodiaq”, page 90
3.7.1 Removing and installing the selector

lever control cable, Karoq, Superb III
Removing
– Remove engine cover engine ⇒ Engine; Rep. gr. 10

• The catch can only be released and the selector lever cable
disconnected from the shift mechanism in this position.

– Lift off with a screwdriver and remove cover at the bottom from
the shift mechanism -arrow-.
• Replace cover for shift mechanism after disassembly.
– Using a screwdriver, pull the cable from the shift lever in the
-direction of the arrow-.
– Remove the lock washer -arrow- and detach the selector lever
cable.
• Replace the lock washer after removing it.
– Pull the selector lever control cable on one side out of the shift
mechanism and on the other side out of the cable support/
gearbox and remove.
Installing
• Do not bend or buckle the selector lever control cable.
The cable can only be locked in this position.
– Push cable onto selector lever in the shift mechanism and se‐
cure with new lock washer.
– Close shift mechanism at the bottom with new cover.
– Fit selector lever control cable with cable support to gearbox

with screws -2-.
• Do not yet push the ball head -1- of the selector lever control
cable onto the gearshift lever. Only press on after checking
and adjusting the control cable.
shaft .
silencers .
piece .
– Fasten both underfloor trim panels ⇒ General body repairs,
ble”, page 95 .
Note


49
3.7.2 Removing and installing the selector

lever control cable - Kodiaq
Removing
– Remove engine cover engine ⇒ Engine; Rep. gr. 10



body repairs, exterior; Rep. gr. 66 ; Underfloor trim panel .
– Detach the plug from the bottom part of the shift mechanism
and take off the lock washer for the selector lever cable
-arrow-.

– Pull the selector lever cable out of the shift mechanism and
remove.
Installing
• After installing the shift mechanism, check the selector lever
control cable for ease of movement and adjust.
– Insert the selector lever cable into the shift mechanism far
enough for it to be visible in the catch for the shift mechanism
-arrow-.


• The selector lever cable is secured once the recesses of the

catch are at right angles to the end of the cable.
– Install a new lock washer -arrow- and insert plug.
– Fit selector lever control cable with cable support to gearbox

with screws -2-.
• Do not yet push the ball head -1- of the selector lever control
cable onto the gearshift lever. Only press on after checking
and adjusting the control cable.
General body repairs, exterior; Rep. gr. 66 ; Underfloor trim
panel .
shaft .
silencers .
piece .
– Fasten both underfloor trim panels ⇒ General body repairs,
ble”, page 95 .
Note


49

3.8 Inspecting and adjusting the selector

lever control cable
⇒ “3.8.1 Checking and adjusting the selector lever control cable,
Karoq, Kodiaq, Superb III”, page 95
⇒ “3.8.2 Adjusting the selector lever control cable, Octavia IV”,
page 96
3.8.1 Checking and adjusting the selector lev‐

er control cable, Karoq, Kodiaq, Superb
III
• To check that the selector lever control cable is moving freely,
the control cable has to be separated from the gearbox.
• Place the remove end so that it is not touching anything else
at any point.
• After checking the control cable, fit and adjust to the gearbox
again.
Checking
– Remove the battery with battery tray ⇒ Electrical system; Rep.
gr. 27 ; Battery; Removing and installing battery tray .
– Slide the selector lever from position “P” to position “S” several
times.
• Selector lever must move freely in this case.
Setting
The selector lever control cable must be adjusted if:
♦ the selector lever control cable has been removed from the
gearbox
♦ Engine or gearbox was removed and installed
♦ Parts of the assembly bracket have been removed and instal‐
led
♦ The shift mechanism or the selector lever control cable itself
has been removed.
– Shift selector lever in the vehicle into position “P”.
• The gearshift shaft must be in position “P”.
• To check position “P”, turn both front wheels in one direction,
e.g. by pushing the vehicle forwards, until the locking lever in
the gearbox engages into the park lock and the front wheels
are blocked (cannot be simultaneously turned in one direc‐
tion).
– Loosen adjusting screw -arrow- for selector lever control ca‐

ble.
– Slightly move the selector lever towards the front and rear,
without shifting into another selector lever position.
– Tighten clamping bolt -arrow- on selector lever cable smooth‐
ly.
• Pay attention when tightening the clamping screw -arrow- that
the selector lever control cable no longer shifts.
– Install the battery with battery tray ⇒ Electrical system; Rep.
3.8.2 Adjusting the selector lever control ca‐

ble, Octavia IV
The selector lever control cable must be adjusted if:
♦ the selector lever control cable has been removed from the
gearbox
♦ Engine or gearbox was removed and installed
♦ Parts of the assembly bracket have been removed and instal‐
led
♦ The gearshift mechanism has been removed with the selector
lever control cable
♦ Adjustment element of the cable for shift mechanism was re‐
moved

– Switch into the “P” position by pressing the button.

• The cable is fastened to the gearbox, the mounting screws
-1- are tightened.
• The cable end -2- remains loose in the actuator lock -3-.
• The “P” position is required to set the selector lever control
cable correctly on the gearshift mechanism, as well as on the
gearshift shaft.
Check the “P” position on the gearshift shaft.
The gearshift shaft is in the “P” position when the gearshift lever
on gearbox -1- is pressed in the rear position (rear position to‐
wards the interior of the vehicle).
The figure shows the gearshift lever without an actuator or control
cable.
– Press the gearshift lever -1- in the direction of the -arrow- to‐
wards the interior of the vehicle.
The gearshift lever can still be pressed slightly behind the last
position, in which case the lever returns to the last position. The
last position is the correct “P” position.
• A check can also be carried out as follows to see whether the
“P” position has been engaged, turn both front wheels in one
direction, e.g. by pushing the vehicle forwards, until the locking
lever in the gearbox engages into the park lock and the front
wheels are blocked (cannot be simultaneously turned in one
direction).
– Rotate the actuator lock adjustment mechanism for the control

cable -1- in the -direction of arrow A- until it stops.
• The control cable -B- must move freely in the lock.
The spring presses the locking mechanism back into its original
position -direction of arrow B-.
The selector lever control cable is now adjusted.
3.9 Installing the lock button at the selector

lever handle
The lock button -2- at the selector lever handle protrudes in its
installed position.
• If the lock button -2- was inadvertently pressed in, it must then
be repositioned in order to fit the selector lever handle.
– Carefully guide the release tool - T40203- fully into the selector
lever handle -1- -arrow-.
Note
The selector lever handle in the illustration is shown without the

selector lever collar. The selector lever collar does not separate
from the handle.
• The recess at the release tool - T40203- points to the lock

button and the hook points to the left.
– Hold the selector lever handle -A- and turn the release tool -
T40203- by 180° in -direction of arrow 1-.
– Hold the selector lever handle and carefully pull out the release
tool - T40203- -arrow 2-.

• When pulling out the release tool - T40203- , the lock button
at the selector lever handle -A- is pressed in and locked.
• Do not touch and press in the lock button again before instal‐
ling the selector lever handle.
3.10 Replacing cable adjusting element

⇒ “3.10.1 Replacing the control cable adjuster, Superb III, Kodiaq,
Karoq”, page 99
⇒ “3.10.2 Replacing the control cable adjuster, Octavia IV”, page
100
3.10.1 Replacing the control cable adjuster,

Superb III, Kodiaq, Karoq
Removing
– Loosen the adjusting screw -1- for the selector lever control
cable.
– Push adjustment element ball socket -2- of selector lever con‐
trol cable off the gearshift lever with the unlocking tool -
T10236- .
NOTICE
Do not bend or buckle the selector lever control cable.
– Remove the adjusting screw -1- for the selector lever control
cable.
– Pull adjusting element -2- off the end of the selector cable.
Installing
• After installing the adjusting element, adjust the shift mecha‐
nism cable
ble”, page 95 .
Specified torques
♦ Adjustment screw for shift mechanism
49
3.10.2 Replacing the control cable adjuster,

Octavia IV
Removing
• The cable is fastened to the gearbox, do not loosen the mount‐
ing screws -1-.

– Push adjustment element ball socket -1- of selector lever con‐

trol cable off the gearshift lever with the unlocking tool -
T10236- .
– Remove the control cable adjuster -1- from the end of the se‐
lector lever control cable -2-.
NOTICE
Installing
– Fit the actuator for shift mechanism -1- into the end of the cable
-2- and press the ball socket into the gearshift lever.
• Do not release the actuator and leave the lock in the pulled
position. The end of the cable can move freely in the lock. The
lock is only polled when adjusting the selector lever control
cable.
– Adjust cable for shift mechanism
ble”, page 95 .
Specified torques
♦ Adjustment screw for shift mechanism
49
3.11 Replacing the sealing ring for the gear‐

shift shaft
⇒ “3.11.1 Replacing the gearshift shaft seal, Karoq, Kodiaq, Su‐
perb III”, page 101
⇒ “3.11.2 Replacing the gearshift shaft sealing ring, Octavia IV”,
page 103
3.11.1 Replacing the gearshift shaft seal, Kar‐

oq, Kodiaq, Superb III
♦ Pipe section - MP3-479 (VW 423)-


– Unscrew screws -2-, detach cable support for selector lever
control cable from gearbox -3- and place to one side.
NOTICE
Risk of damage to the selector lever control cable.
– Do not bend or kink selector lever control cable too much,
otherwise it will be damaged.
– Unscrew screw -arrows- and remove gearshift lever -1-.
– Lever out the sealing ring for gearshift shaft with the extractor
tool - T20143/1- -arrow-.
– Lubricate the outer surface and sealing lips of the new sealing
ring with gear oil.
– Fill half the space between the sealing lip and dust lip
-arrow- with sealing grease ⇒ Electronic Catalogue of Original
Parts .

– Drive in new sealing ring with pipe section - MP3-479 (VW

423)- -1- up to the stop.
• The sealing ring must stay straight as it is driven in.
– Fit the gearshift lever -1- to the park lock shaft and tighten the
bolt -arrow-.
– Fit cable support with selector lever control cable to gearbox

with bolts -2- and push the ball socket -1- onto the gearshift
lever.
ble”, page 95 .
Note


49
3.11.2 Replacing the gearshift shaft sealing

ring, Octavia IV
♦ Pipe section - MP3-479 (VW 423)-


– Remove the cable control adjustment element for shift mech‐
anism ⇒ “3.10 Replacing cable adjusting element”, page 99 .
NOTICE
– Unscrew screw -arrows- and remove gearshift lever -1-.
– Lever out the sealing ring for gearshift shaft with the extractor
tool - T20143/1- -arrow-.
– Lubricate the outer surface and sealing lips of the new sealing
ring with gear oil.
– Fill half the space between the sealing lip and dust lip
-arrow- with sealing grease ⇒ Electronic Catalogue of Original
Parts .

– Drive in new sealing ring with pipe section - MP3-479 (VW

423)- -1- up to the stop.
• The sealing ring must stay straight as it is driven in.
– Fit the gearshift lever -1- to the park lock shaft and tighten the
bolt -arrow-.
– Install the control cable adjustment element for shift mecha‐
nism ⇒ “3.10 Replacing cable adjusting element”, page 99 .
Note


49

4 Removing and installing the gearbox

⇒ “4.1 Tightening torques for gearbox”, page 106
⇒ “4.2 Removing the gearbox”, page 108
⇒ “4.3 Installing the gearbox”, page 207
4.1 Tightening torques for gearbox

Vehicles with 2.0 TDI CR engine
Position Screw Nm
1.2 M12 x 50 80
When using the insertion tool - T10509- 65
3 M12 x 60 80
Screw is only accessible through the opening after removing the starter
4 M12 x 60 80
5, 6, 7 M10 x 50 40
8 M12 x 70 80
Screw is accessible from the engine side
A Dowel sleeves
Vehicles with 1.5 l TSI engine
Position Screw Nm
1.2 M12 x 70 80
3 M12 x 70 80
4 M12 x 80 80
5, 6, 7 M10 x 60 40
8.9 M12 x 80 80

Position Screw Nm
A Dowel sleeves
Vehicles with 2.0 TFSI engine
Position Screw Nm
1.2 M12 x 60 80
3 M12 x 60 80
4 M12 x 80 80
5, 6, 7 M10 x 60 40
8 M12 x 80 80
A Dowel sleeves
4. Removing and installing the gearbox 107

4.2 Removing the gearbox

⇒ “4.2.1 Removing gearbox, Superb III, vehicles with diesel en‐
gine 2.0 l TDI CR, front wheel drive”, page 108
gine 2.0 l TDI CR, all-wheel drive”, page 116
⇒ “4.2.3 Removing the gearbox, Superb III, vehicles with 2.0 TFSI
petrol engines, front-wheel drive”, page 125
gine 2.0 l TDI CR, four-wheel drive”, page 132
⇒ “4.2.5 Removing the gearbox , Karoq, vehicles with 1.5 l TSI
petrol engines, all-wheel drive”, page 139
⇒ “4.2.6 Removing the gearbox, Karoq, vehicles with 2.0 l TFSI
petrol engines, four-wheel drive”, page 146
⇒ “4.2.7 Removing gearbox, Karoq, vehicles with diesel engine
2.0 lTDI CR, all-wheel drive”, page 155
⇒ “4.2.8 Removing the gearbox, Kodiaq, vehicles with 1.5 TSI
petrol engine, front-wheel drive”, page 163
⇒ “4.2.9 Removing gearbox, Kodiaq, vehicles with diesel engine
2.0 TDI CR, front wheel drive”, page 169
⇒ “4.2.10 Removing the gearbox , Karoq, vehicles with 1.5 l TSI
petrol engines, four-wheel drive”, page 176
⇒ “4.2.11 Removing the gearbox , Kodiaq, vehicles with 2.0 l TFSI
petrol engines, all-wheel drive”, page 183
⇒ “4.2.12 Removing gearbox, Kodiaq, vehicles with diesel engine
2.0 lTDI CR, four-wheel drive”, page 191
⇒ “4.2.13 Removing the gearbox, Octavia IV, vehicles with diesel
engine 2.0 TDI CR, front-wheel drive”, page 199
4.2.1 Removing gearbox, Superb III, vehicles

with diesel engine 2.0 l TDI CR, front
wheel drive
♦ Hose clamp - MP7-602 (3094)-
♦ Plug set , e.g. -VAS 6122-
♦ Socket insert XZN 14 - T10061-
♦ Interceptor - MP9-200 (10-222A)- or -10-222B-
♦ Carrier part - T40091/1-
♦ Adapter - T40091/3-
♦ Spindle - T40093/3- with adapter - T40093/3-6A-
♦ Hooks - MP9-200/10 (10-222A/10)- x2
♦ Shackle - 10-222A/12-
♦ Gearbox mount - 3282-
♦ Bolt - 3282/34-
♦ Engine and gearbox jack , e.g. -V.A.G 1383A- or -VAS 6931-

• General repair information ⇒ “3 Repair instructions”, page 6 .

• All cable straps that are detached or cut when removing should
be attached again in the same place when installing.
– Remove the plenum panel cover ⇒ External body repairs;
Rep. gr. 50 ; Bulkhead; Assembly overview - plenum panel
cover .
– Remove the engine cover panel ⇒ Rep. gr. 10 ; Engine cover
panel; removing and installing engine cover panel .
– Remove air filter housing ⇒ Rep. gr. 23 ; Air filter; Removing
and installing air filter housing .
– Lift off ventilator -1- (if fitted) with breather hose from the lock
-arrow- on the battery tray -3-.
• If the bleed hose is withdrawn from the exhaust pipe of the

gearbox, the exhaust pipe must be sealed with a cap
-arrow-.
• The cap should prevent dirt from entering the transmission.

– Remove screws -arrows-, release clamp -3- and remove

charge air pipe.
Ignore clamp -2-.
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
Removing and installing starter .
CAUTION
There is overpressure in the cooling system when the engine is
at normal operating temperature.
There is a risk of injury from hot coolant or hot steam.
– Slowly open the cap of the compensation bottle, in order to
first reduce pressure before pulling off the coolant hoses.
• Do not place fluffing cloths on the gearbox oil cooler and the
gearbox, in order to collect flowing out coolant.
• Mark the coolant hoses to the gearbox oil cooler in order to
prevent interchanging when installing.
– Clamp off the coolant hoses with the hose clamps - MP7-602
(3094)- -A-.
– Slacken hose clamps -arrows- and remove hoses from gear‐
box oil cooler.
– Close gearbox oil cooler with a clean plug e.g. from the plug
set - VAS 6122- .
NOTICE
tronics - J743- .
tronics.

– Turn the cap in -direction of arrow- and disconnect electrical

plug connection from the dual clutch gearbox mechatronics -
J743- .
• Lay the electric cables to the side.

– Remove connecting screws for the top engine/gearbox -1-,

-2- and -3-.
The screws -1- and -2- (previous figure S34–10164) can be re‐
moved with an insertion tool - T10509- .
The screw -3- (previous figure S34–10164) is located in the starter

opening -arrow- and can be removed with plug insert XZN 14 -
T10061- .
Install interception device to catch the engine/gearbox assembly.
The following special tools are required for attaching the inter‐
ceptor :
♦ Adapter - T40091/3-
♦ Hooks - MP9-200/10 (10-222A/10)- x2
♦ Shackle - 10-222A/12-
• There are hose lines and cables in the engine mounting eyelet
area for the interceptor , which now need to be removed.

– Push the release buttons on the crankcase ventilation hose

-4-, and remove the hose.
– Remove the plug on the hose -4- (if present).
– Detach vacuum hoses -2- and -3-.
– Detach hose clamps -5- and remove in intake hose -1-.
• Before installing the actual interceptor , the adapter -
T40093/3-6A- must be positioned on the right longitudinal
member, which is then connected to the spindle - T40093/3- .
• To set this up, the fuel filter must be removed.
• The fuel filter this detached from the bracket on the body, do
not disconnect the fuel lines.
– Unlock the plug connection -3- and disconnect.

– Remove bracket for connector from fuel filter housing.
– Screw out the fixing screws of the fuel filter -2-.

– Unscrew nut -1-.
– Place the fule filter with connected fuel hoses on the engine.
– Position adapter - T40093/3-6A- on the right-hand longitudinal

member as shown in the figure.
• Remove the air conditioning system’s refrigerant pipe from the
bracket, if required.
• The adapter must be secured by the bolt -A- to the flange of
the frame side rail -arrow-.
– Screw the spindle - T40093/3- onto the adapter -
T40093/3-6A- .
The spindle - T40093/3- is then connected to the support part -
T40091/1- (see further workflow).

– Remove the right and left foam parts -arrows- for the water
tank seal.
– Attach the adapter - T40091/3- -D- to the carrier -B- for the
interceptor - MP9-200 (10-222A)- or -10-222B- .
– At the same time push -B- the hook - MP9-200/10 (10-222A/
10)- onto the carrier, as shown in the following figure
N10-11147.
– Remove the -B- support adapter -A- and fit the interceptor onto
the longitudinal members.
• Align the support adapter -A- with the recess on both sides
-arrow-.
– Connect the interceptor -B- using the carrier - T40091/1- -D-

to the spindle - T40093/3- -G-.
A - Adapter from the interceptor set
B - Interceptor - MP9-200 (10-222A)- or -10-222B-
C - Adapter - T40091/3-
D - Carrier part - T40091/1-
E - Hook - MP9-200/10 (10-222A/10)-
F - Shackle - 10-222A/12-
G - Spindle - T40093/3- with adapter - T40093/3-6A-
– With spindle -G- align carrier -D- horizontally and tighten all
interlocking elements with locking screws .
– Slightly pre-tension the engine/gearbox assembly via the
hooks - MP9-200/10 (10-222A/10)- (do not raise).
Component Tightening torque

M12 screws for the supporting device 20 Nm
Continuation Remove transmission

– Remove the front left wheelhouse liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheelhouse liner; removing and
installing front wheelhouse liner .
– Remove assembly carrier without steering gear ⇒ Chassis,
axles, steering; Rep. gr. 40 ; Removing and installing assem‐
bly carrier without steering gear .

– Disconnect connector for auxiliary hydraulic pump 1 for gear

oil - V475- .
– Remove the left and right propeller shafts from the flange
shafts on the gearbox ⇒ Chassis, axles, steering; Rep. gr.
40 ; Propeller shaft; remove and install propeller shaft .
– Secure both drive shafts to the suspension strut with tension‐

ing straps - T10038- .
• Ensure that the surface protection of the drive shafts is not
damaged.
– Unscrew and remove bottom connecting bolts of engine/gear‐

box -4-, -5-, -6- and -7-.
• The last connecting -screw 8-, which is screwed in from the
engine side, can only be loosened and screwed in.

– Unscrew the screws -arrows- from the gearbox mount.
– Lower the engine/gearbox unit via the spindle of the support‐

ing device by dimension -a-.
• Dimension -a- = approx. 90 mm
– Place the gearbox mount - 3282- onto engine/gearbox jack ,
e.g. -V.A.G 1383A- or -VAS 6931- .
– Position the engine / gearbox jack below the vehicle with the
gearbox mount - 3282- .
– Align the gearbox mount - 3282- parallel to the gearbox.
– Place the individual elements of the gearbox mount - 3282- to

the gearbox, as shown in the figure.
– Insert the fixing hook -1- into the bore on the gearbox housing
(next to the oil drain plug for mechatronics).
– Put circlip -2- in the groove of the gearbox housing.
– Screw the bolt - 3282/34- into the threaded hole for the pen‐
dulum support and connect it to the gear holder - 3282- .
– Insert the fourth adapter (bolt) from below into the bore of the
gearbox.
– Support the gearbox with engine / gearbox jack from under‐
neath.
– Remove remaining engine/gearbox connecting bolt.
– Press the gearbox out of the sleeves.
– Carefully separate the gearbox from the engine and lower
slowly.
• Observe all lines and coolant hoses when lowering the gear‐
box.
Transport gearbox ⇒ “6 Transporting the gearbox”, page 217 .
Secure on assembly support
⇒ “7 Attachment at engine and gearbox mount”, page 218 .


with diesel engine 2.0 l TDI CR, all-
wheel drive
♦ Hose clamp - MP7-602 (3094)-
♦ Adapter - T40091/3-
♦ Hooks - MP9-200/10 (10-222A/10)- x2
♦ Shackle - 10-222A/12-
♦ Bolt - 3282/34-
For vehicles with four-wheel drive, switch the selector lever to
position “N” so that it is then possible to turn using the propshaft
when loosening.
cover .


-arrow-.


charge air pipe.
Ignore clamp -2-.
CAUTION
(3094)- -A-.
box oil cooler.
set - VAS 6122- .
NOTICE
tronics - J743- .
tronics.


J743- .


-2- and -3-.

T10061- .
ceptor :
♦ Adapter - T40091/3-
♦ Hooks - MP9-200/10 (10-222A/10)- x2
♦ Shackle - 10-222A/12-
• There are hose lines and cables in the engine mounting eyelet
area for the interceptor , which now need to be removed.

– Push the release buttons on the crankcase ventilation hose

-4-, and remove the hose.
– Remove the plug on the hose -4- (if present).
– Detach vacuum hoses -2- and -3-.
– Detach hose clamps -5- and remove in intake hose -1-.
• Before installing the actual interceptor , the adapter -
T40093/3-6A- must be positioned on the right longitudinal
member, which is then connected to the spindle - T40093/3- .
• To set this up, the fuel filter must be removed.



• Remove the air conditioning system’s refrigerant pipe from the
bracket, if required.
– Screw the spindle - T40093/3- onto the adapter -
T40093/3-6A- .
The spindle - T40093/3- is then connected to the support part -
T40091/1- (see further workflow).

– Remove the right and left foam parts -arrows- for the water
tank seal.
– Attach the adapter - T40091/3- -D- to the carrier -B- for the
interceptor - MP9-200 (10-222A)- or -10-222B- .
– At the same time push -B- the hook - MP9-200/10 (10-222A/
10)- onto the carrier, as shown in the following figure
N10-11147.
– Remove the -B- support adapter -A- and fit the interceptor onto
the longitudinal members.
• Align the support adapter -A- with the recess on both sides
-arrow-.
– Connect the interceptor -B- using the carrier - T40091/1- -D-

to the spindle - T40093/3- -G-.
A - Adapter from the interceptor set
C - Adapter - T40091/3-
E - Hook - MP9-200/10 (10-222A/10)-
F - Shackle - 10-222A/12-
- Spindle - T40093/3- with adapter - T40093/3-6A-
– With spindle -G- align carrier -D- horizontally and tighten all
interlocking elements with locking screws .


– Remove the front left and right wheelhouse liner ⇒ General
body repairs, exterior; Rep. gr. 66 ; Wheelhouse liner; remov‐
ing and installing front wheelhouse liner .


oil - V475- .
– Disconnect the connector on the oil level and oil temperature

sender - G266- -1-.
shaft.


damaged.

push to side.
propeller shaft .
– Tie the propshaft to the top so as not to damage paint damage
on the surface of the propshaft.
gearbox.

box -4-, -5-, -6- and -7-.


– Position gearbox mount - 3282- on the engine/gearbox jack -
V.A.G 1383A- .
– Position the engine/gearbox jack -V.A.G 1383A- or -VAS
6931- below the vehicle using the gearbox mount - 3282- .

gearbox.
neath.
slowly.
box.

4.2.3 Removing the gearbox, Superb III, ve‐

hicles with 2.0 TFSI petrol engines,
front-wheel drive
♦ Hose clamp - MP7-602 (3094)-
♦ Interceptor - T30099- or -T30099A-
♦ Surface - T30119-
♦ Support - 10-222A/31-
♦ Adapter - MP9-200/18 (10-222A/18)-
♦ Hook - MP9-200/10 (10-222A/10)-
♦ Clutch - T40091/3-
♦ Bolt - 3282/34-
– Remove screws -1- and -3-.
– Unlock safety strap -arrow- and remove intake cover -2- .

– Remove coolant hose -2- from the clamps on the intake mani‐
fold.
– Unlock safety strap -arrows- and remove the air guide pipe top
-1-.
– Detach vacuum hose -1- from air filter housing.

– Unplug connector -2- for air mass meter - G70- .
– Release hose clamp -3- and remove air duct.
– Undo the air filter housing -4- from the rubber bolts and remove
it upwards.
– Remove screw left and right -arrow-.

– Unclip and remove the air guide pipe bottom -1-.


-arrow-.
cover .
NOTICE
tronics - J743- .
tronics.


J743- .
– Disconnect earth lead from lower starter bolt.
– Loosen hose clamps -1-, -2- and remove air guide hose from
charge-air cooler.

– Expose electric wiring harnesses -1- and -2- at the air guide
pipe.
– Slacken screw clamp -4-.
– Remove screws -arrows- and remove the air guide pipe.
– Seal the open pipes with a clean plug from the plug set , e.g.
-VAS 6122- .
CAUTION
(3094)- -A-.
box oil cooler -1-.
set - VAS 6122- .
– Remove screw -arrow- on coolant tube holder -3-, detach tube

-2- from gearbox and tie up to one side.
The other holder for coolant tube -1- has already been detached
when the starter was previous removed.


-2- and -3-.

T10061- .
Supporting the engine/gearbox assembly
– Remove caps of screwed connections for front suspension
strut domes.
– Attach support bracket together with the other elements ac‐

cording to the illustration.
1 - Supporting plate - T30119-
2 - Support - 10-222A/31-
3 - Adapter - MP9-200/18 (10-222A/18)-
4 - Hook - MP9-200/10 (10-222A/10)-
5 - Interceptor - T30099- or -T30099A-
6 - Adapter - T40091/3-
hooks (do not raise).


oil - V475- .

damaged.

box -4-, -5-, -6- and -7-.


e.g. -V.A.G 1383A- or -VAS 6931- .

gearbox.
neath.
slowly.
box.


with diesel engine 2.0 l TDI CR, four-
wheel drive
♦ Hose clamp - MP7-602 (3094)-
♦ Interceptor - T30099- or -T30099A-
♦ Surface - T30119-
♦ Support - 10-222A/31-
♦ Adapter - MP9-200/18 (10-222A/18)-
♦ Hook - MP9-200/10 (10-222A/10)-
♦ Clutch - T40091/3-
♦ Bolt - 3282/34-
when loosening.

fold.
-1-.

it upwards.



-arrow-.
cover .
NOTICE
tronics - J743- .
tronics.


J743- .
charge-air cooler.

pipe.
– Seal the open pipes with a clean plug from the plug set - VAS
6122- .
CAUTION
(3094)- -A-.
box oil cooler -1-.
set - VAS 6122- .



-2- and -3-.

T10061- .
– Remove caps of screwed connections for front suspension
strut domes.

– Attach support bracket together with the other elements ac‐

cording to the illustration.
1 - Supporting plate - T30119-
2 - Support - 10-222A/31-
3 - Adapter - MP9-200/18 (10-222A/18)-
4 - Hook - MP9-200/10 (10-222A/10)-
5 - Interceptor - T30099- or -T30099A-
6 - Adapter - T40091/3-
hooks (do not raise).
propeller shaft .

oil - V475- .


damaged.
gearbox -1-.

box -4-, -5-, -6- and -7-.


e.g. -V.A.G 1383A- or -VAS 6931- .

gearbox.
neath.
slowly.
box.
4.2.5 Removing the gearbox , Karoq, vehicles

with 1.5 l TSI petrol engines, all-wheel
drive
♦ Hose clamp - MP7-602 (3094)-

♦ Adapter - 10-222A/13-
♦ Hook - MP9-200/10 (10-222A/10)- 2 units
♦ Shackle - 10-222A/12-
♦ Bolt - 3282/34-
when loosening.

-arrow-.

CAUTION
(3094)- -A-.
box oil cooler.
set - VAS 6122- .
NOTICE
tronics - J743- .
tronics.


J743- .


-2- and -3-.

T10061- .
– Fit the supporting device as shown and place on the vehicle.

1 - Hook - MP9-200/10 (10-222A/10)-

2 - Interceptor - MP9-200 (10-222A)- or -10-222B-
3 - Adapter - 10-222A/13-
4 - Shackle - 10-222A/12-
• Adapter - 10-222A/13- -3- With the inscription L is on the right
side of the vehicle.
• Adapter - 10-222A/13- -3- with the inscription R is located on
the left side of the vehicle.
• The arrows on the adapters - 10-222A/13- point forwards in
the direction of travel.
– Slightly pre-tension the engine/gearbox unit via the spindles
of the supporting device .


oil - V475- .

sender - G266- -1-.
shaft.


damaged.
propeller shaft .
gearbox.

box -4-, -5-, -6- and -7-.
• The last connecting screws -8- and -9- , which are screwed in
from the engine side, can only be loosened and screwed in.


V.A.G 1383A- .

gearbox.
neath.
– Remove remaining engine/gearbox connecting screws.
slowly.
box.
4.2.6 Removing the gearbox, Karoq, vehicles

with 2.0 l TFSI petrol engines, four-
wheel drive
♦ Hose clamp - MP7-602 (3094)-

♦ Adapter - 10-222A/13-
♦ Hook - MP9-200/10 (10-222A/10)- 2 units
♦ Bolt - 3282/34-
when loosening.
fold.
-1-.

it upwards.



-arrow-.
cover .

NOTICE
tronics - J743- .
tronics.


J743- .
charge-air cooler.

pipe.
6122- .
CAUTION
(3094)- -A-.
box oil cooler -1-.
set - VAS 6122- .



-2- and -3-.

T10061- .

1 - Hook - MP9-200/10 (10-222A/10)-

2 - Interceptor - MP9-200 (10-222A)- or -10-222B-
3 - Adapter - 10-222A/13-
4 - this position is not used to suspend the 2.0 TFSI gasoline en‐
gine
• Adapter - 10-222A/13- -3- With the inscription L is on the right
• Adapter - 10-222A/13- -3- with the inscription R is located on


propeller shaft .

oil - V475- .

damaged.
gearbox -1-.


box -4-, -5-, -6- and -7-.

e.g. -V.A.G 1383A- or -VAS 6931- .


gearbox.
neath.
slowly.
box.
4.2.7 Removing gearbox, Karoq, vehicles with

diesel engine 2.0 lTDI CR, all-wheel
drive
♦ Hose clamp - MP7-602 (3094)-
♦ Adapter - MP9-200/18 (10-222A/18)- (2 units)
♦ Adapter - 10-222A/13-
♦ Hook - MP9-200/10 (10-222A/10)-
♦ Shackle - 10-222A/12-
♦ Bolt - 3282/34-
when loosening.


-arrow-.


charge air pipe.
Ignore clamp -2-.
CAUTION
(3094)- -A-.
box oil cooler.
set - VAS 6122- .
NOTICE
tronics - J743- .
tronics.


J743- .


-2- and -3-.

T10061- .

A - Adapter - MP9-200/18 (10-222A/18)-

C - Adapter - 10-222A/13-
D - Hook - MP9-200/10 (10-222A/10)-
E - Shackle - 10-222A/12-
• Adapter - 10-222A/13- -C- with the inscription L is on the right
• Adapter - 10-222A/13- -C- with the inscription R is located on


oil - V475- .

sender - G266- -1-.
shaft.


damaged.

push to side.
propeller shaft .
gearbox.

box -4-, -5-, -6- and -7-.


V.A.G 1383A- .

gearbox.
neath.
slowly.
box.

4.2.8 Removing the gearbox, Kodiaq, vehi‐

cles with 1.5 TSI petrol engine, front-
wheel drive
♦ Hose clamp - MP7-602 (3094)-
♦ Adapter - 10-222A/29-
♦ Spindle - T40093/3-
♦ Clutch - T40091/3-
♦ Adapter - MP9-200/18 (10-222A/18)-
♦ Hook - MP9-200/10 (10-222A/10)- 2 units
♦ Shackle - 10-222A/12-
♦ Adapter - T40093/3-6- or -T40093/3-6A-
♦ Bolt - 3282/34-


-arrow-.
CAUTION

(3094)- -A-.
box oil cooler.
set - VAS 6122- .
NOTICE
tronics - J743- .
tronics.


J743- .

-2- and -3-.
The screws -1- and -2- (previous figure N34–12603) can be re‐

The screw -3- (previous figure N34–12603) is located in the starter

T10061- .
• To fit the supporting device , the cross member must be de‐
tached on the right side of the vehicle.
The member is located in the area underneath the right wheel‐
house liner.
Detaching the cross member creates a space to fit the spindle -
T40093/3- with adapter - T40093/3-6- or -T40093/3-6A- for the
supporting device .
– Remove the front right wheelhouse liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheelhouse liner; Removing and
installing the front wheelhouse liner .
– Unscrew screws -arrows- and detach the cross member from

the front wall.
• If hose and cable connections are located in the area of the
lifting eyes of the engine for the supporting device , these must
now be removed.
– Fit the adapter - 10-222A/29- -1- to the body under the wing
plate on both sides of the vehicle, as shown.
• Adapter with symbol “L” is installed on the “right” side of the
vehicle.
• Adapter with symbol “R” is installed on the “left” side of the
vehicle.
• The arrow shows the direction of travel on each side.

– Assemble the interceptor - MP9-200 (10-222A)- or -10-222B-

together with the other elements as shown in the figure.
A - Adapter - 10-222A/29-
C - Spindle - T40093/3-
E - Connecting crosspiece - T40091/3-
F - Adapter - MP9-200/18 (10-222A/18)-
G - Hook - MP9-200/10 (10-222A/10)-
H - Hook - MP9-200/10 (10-222A/10)-
I - Shackle - 10-222A/12-
J - Adapter - T40093/3-6- or -T40093/3-6A-
– Position adapter - T40093/3-6- or -T40093/3-6A- on the frame

side rail as shown.
• The adapter - T40093/3-6- or -T40093/3-6A- must be secured
by bolt -A- to the flange of the frame side rail -arrow-.
• Connect adapter - T40093/3-6- or -T40093/3-6A- to the spin‐
dle - T40093/3- of the supporting device and pre-tension sup‐
porting device using the assembled spindle.
of the interceptor (do not raise).


oil - V475- .

damaged.

box -4-, -5-, -6- and -7-.


e.g. -V.A.G 1383A- or -VAS 6931- .

gearbox.
neath.
slowly.
box.
4.2.9 Removing gearbox, Kodiaq, vehicles

with diesel engine 2.0 TDI CR, front
wheel drive
♦ Hose clamp - MP7-602 (3094)-

♦ Adapter - 10-222A/29-
♦ Spindle - T40093/3-
♦ Clutch - T40091/3-
♦ Adapter - MP9-200/3 (10-222A/3)-
♦ Hook - MP9-200/10 (10-222A/10)- 2 units
♦ Shackle - 10-222A/12-
♦ Adapter - T40093/3-6- or -T40093/3-6A-
♦ Bolt - 3282/34-

-arrow-.


charge air pipe.
Ignore clamp -2-.
CAUTION
(3094)- -A-.
box oil cooler.
set - VAS 6122- .
NOTICE
tronics - J743- .
tronics.



J743- .

-2- and -3-.

T10061- .
house liner.
supporting device .


the front wall.
now be removed.
vehicle.
vehicle.

A - Adapter - 10-222A/29-
C - Spindle - T40093/3-
F - Adapter - MP9-200/3 (10-222A/3)-
G - Hook - MP9-200/10 (10-222A/10)-
H - Hook - MP9-200/10 (10-222A/10)-
I - Shackle - 10-222A/12-
J - Adapter - T40093/3-6- or -T40093/3-6A-


side rail as shown.

oil - V475- .

damaged.


box -4-, -5-, -6- and -7-.

e.g. -V.A.G 1383A- or -VAS 6931- .


gearbox.
neath.
slowly.
box.
4.2.10 Removing the gearbox , Karoq, vehicles

with 1.5 l TSI petrol engines, four-wheel
drive
♦ Hose clamp - MP7-602 (3094)-
♦ Adapter - 10-222A/29-
♦ Spindle - T40093/3-
♦ Clutch - T40091/3-
♦ Adapter - MP9-200/18 (10-222A/18)-
♦ Hook - MP9-200/10 (10-222A/10)- 2 units
♦ Shackle - 10-222A/12-
♦ Adapter - T40093/3-6- or -T40093/3-6A-
♦ Bolt - 3282/34-
when loosening.



-arrow-.
CAUTION

(3094)- -A-.
box oil cooler.
set - VAS 6122- .
NOTICE
tronics - J743- .
tronics.


J743- .

-2- and -3-.


T10061- .
house liner.
supporting device .

the front wall.
now be removed.
vehicle.
vehicle.


A - Adapter - 10-222A/29-
C - Spindle - T40093/3-
F - Adapter - MP9-200/18 (10-222A/18)-
G - Hook - MP9-200/10 (10-222A/10)-
H - Hook - MP9-200/10 (10-222A/10)-
I - Shackle - 10-222A/12-
J - Adapter - T40093/3-6- or -T40093/3-6A-

side rail as shown.


oil - V475- .
shaft.

damaged.
propeller shaft .
gearbox.


box -4-, -5-, -6- and -7-.

V.A.G 1383A- .


gearbox.
neath.
slowly.
box.
4.2.11 Removing the gearbox , Kodiaq, vehi‐

cles with 2.0 l TFSI petrol engines, all-
wheel drive
♦ Hose clamp - MP7-602 (3094)-
♦ Adapter - 10-222A/29-
♦ Spindle - T40093/3-
♦ Clutch - T40091/3-
♦ Adapter - MP9-200/18 (10-222A/18)-
♦ Hook - MP9-200/10 (10-222A/10)- 2 units
♦ Shackle - 10-222A/12-
♦ Adapter - T40093/3-6- or -T40093/3-6A-
♦ Bolt - 3282/34-
when loosening.


fold.
-1-.

it upwards.



-arrow-.
cover .
NOTICE
tronics - J743- .
tronics.



J743- .
charge-air cooler.
pipe.
6122- .
CAUTION

(3094)- -A-.
box oil cooler -1-.
set - VAS 6122- .


-2- and -3-.


T10061- .
house liner.
T40093/3- with adapter - T40093/3-6- or for the supporting device
- T40093/3-6A- .

the front wall.
now be removed.
vehicle.
vehicle.

A - Adapter - 10-222A/29-
C - Spindle - T40093/3-
F - Adapter - MP9-200/18 (10-222A/18)-
G - Hook - MP9-200/10 (10-222A/10)-
H - Hook - MP9-200/10 (10-222A/10)-
I - Shackle - 10-222A/12-
J - Adapter - T40093/3-6- or -T40093/3-6A-


side rail as shown.

oil - V475- .

damaged.
propeller shaft .

gearbox -1-.

box -4-, -5-, -6- and -7-.

e.g. -V.A.G 1383A- or -VAS 6931- .


gearbox.
neath.
slowly.
box.
4.2.12 Removing gearbox, Kodiaq, vehicles

with diesel engine 2.0 lTDI CR, four-
wheel drive
♦ Hose clamp - MP7-602 (3094)-
♦ Adapter - 10-222A/29-
♦ Spindle - T40093/3-
♦ Clutch - T40091/3-
♦ Adapter - MP9-200/3 (10-222A/3)-
♦ Hook - MP9-200/10 (10-222A/10)- 2 units
♦ Shackle - 10-222A/12-
♦ Adapter - T40093/3-6- or -T40093/3-6A-


♦ Bolt - 3282/34-
when loosening.

-arrow-.


charge air pipe.
Ignore clamp -2-.
CAUTION
(3094)- -A-.
box oil cooler.
set - VAS 6122- .
NOTICE
tronics - J743- .
tronics.



J743- .

-2- and -3-.

T10061- .
house liner.
supporting device .


the front wall.
now be removed.
vehicle.
vehicle.

A - Adapter - 10-222A/29-
C - Spindle - T40093/3-
F - Adapter - MP9-200/3 (10-222A/3)-
G - Hook - MP9-200/10 (10-222A/10)-
H - Hook - MP9-200/10 (10-222A/10)-
I - Shackle - 10-222A/12-
J - Adapter - T40093/3-6- or -T40093/3-6A-


side rail as shown.

oil - V475- .
shaft.


damaged.

push to side.
propeller shaft .
gearbox.

box -4-, -5-, -6- and -7-.


V.A.G 1383A- .

gearbox.
neath.
slowly.
box.

4.2.13 Removing the gearbox, Octavia IV, ve‐

hicles with diesel engine 2.0 TDI CR,
front-wheel drive
♦ Hose clamp - MP7-602 (3094)-
♦ Adapter - 10-222A/29-
♦ Spindle - T40093/3- using Adapter - T40093/3-6A- 2x
♦ Support part - T40091/1- 2x
♦ Adapter - T40091/3- 2x
♦ Adapter - MP9-200/18 (10-222A/18)-
♦ Hooks - MP9-200/10 (10-222A/10)- x2
♦ Shackle - 10-222A/12-
♦ Bolt - 3282/34-


-arrow-.

– Remove the screws -1- for the selector lever control cable
support.
– Remove the selector lever cable -2- from the actuator -3- and
tie it upwards.
removal.

charge air pipe.
Ignore clamp -2-.
CAUTION

(3094)- -A-.
box oil cooler.
set - VAS 6122- .
NOTICE
tronics - J743- .
tronics.


J743- .

-2- and -3-.


T10061- .
now be removed.
ceptor :
♦ Adapter - 10-222A/29-
♦ Spindle - T40093/3- using Adapter - T40093/3-6A- 2x
♦ Support part - T40091/1- 2x
♦ Adapter - T40091/3- 2x
♦ Adapter - MP9-200/18 (10-222A/18)-
♦ Hooks - MP9-200/10 (10-222A/10)- x2
♦ Shackle - 10-222A/12-
• Before setting up the actual interceptor , the adapters -
T40093/3-6A- must be positioned on the longitudinal mem‐
bers.
• On the right side of the vehicle, the fuel filter must be removed
for attaching the spindle - T40093/3- using the adapter -
T40093/3-6A- .




– Disconnect plastic holder with electrical lead from left side
member and place laterally, so that a second adapter -
T40093/3-6A- can be positioned.
– Remove the expansion clip -1- and push the filler neck -3- of
the windscreen washer tank out of the bearing -2-.
– Loosen the filler neck -3- and move it to the side so that the
spindle - T40093/3- can be positioned with the adapter -
T40093/3-6A- .
– Position adapter - T40093/3-6A- on the left side member, just

behind the windscreen washer tank filler pipe, as shown in the
figure.
– Screw spindles - T40093/3- on both adapters - T40093/3-6A- .
Both spindles - T40093/3- are subsequently connected with
straps - T40091/1- (see further workflow).
now be removed.

• Installation position of adapter - 10-222A/29- -1-.

• The adapters - 10-222A/29- are immediately positioned be‐
hind the foam seals of the water box on the right and left
-arrow-.
vehicle.
vehicle.

A - Adapter - 10-222A/29-
C - Spindle - T40093/3- using Adapter - T40093/3-6A-
E - Adapter - T40091/3-
F - Adapter - MP9-200/18 (10-222A/18)-
G - Hook - MP9-200/10 (10-222A/10)-
H - Shackle - 10-222A/12-
– Using spindles - T40093/3- -C- align the carriers - T40091/1-

-D- horizontally on the right and left sides and tighten all
interlocking elements with locking screws.


– Remove wheels at the front.


oil - V475- .

damaged.

box -4-, -5-, -6- and -7-.


e.g. -V.A.G 1383A- or -VAS 6931- .

gearbox.
neath.
slowly.
box.

4.3 Installing the gearbox

⇒ “4.3.1 Installing the gearbox, vehicles with front-wheel-drive”,
page 207
⇒ “4.3.2 Installing the gearbox, vehicles with all-wheel drive”,
page 210
4.3.1 Installing the gearbox, vehicles with

front-wheel-drive

• When installing the new gearbox, adapt die immobiliser ⇒ Ve‐

hicle diagnostic tester.
• Replace needle bearing -arrow- in the crankshaft ⇒ Rep. gr.
13 ; Crankshaft; replace needle bearing in the crankshaft .
• Lubricate the bolt and serration lightly with correct high-tem‐
perature grease ⇒ Electronic Catalogue of Original Parts .
• Check whether the dowel sleeves -A- for centering the gear‐
box are present in the cylinder block, insert if necessary.
• Check that the intermediate plate is seated correctly between
engine and gearbox.
moved.
• Use new screws which must be tightened to a torque angle as
well as sealing rings and seals.
• Secure all hose connections with hose clamps which comply
with the series design ⇒ Electronic Catalogue of Original
Parts .
– Carefully raise gearbox with engine/gearbox jack and bring it
to its installation position using the spindles of the gearbox
mount - 3282- .
• The engine and gearbox must be in line.
• Slide in the engine and gearbox by hand until the engine flange
and the gearbox flange are in contact.
• If necessary, you can turn the crankshaft.
• Do no trap any lines when inserting the gearbox.
– Screw on gearbox to the engine
⇒ “4.1 Tightening torques for gearbox”, page 106 .
– Remove the gearbox mount - 3282- from the gearbox.
– Evenly lift up the gearbox via the hooks of the supporting de‐
vice to the supporting arm of the gearbox mount.
NOTICE
Risk of damage to thread for gearbox console.
– Before screwing in the screws, the gearbox console and
supporting arm of the gearbox mount must be completely
parallel to each other.

– Insert new bolts -arrows- for gearbox mount and tighten at first
by hand.
– Adjust the engine/gearbox unit ⇒ Rep. gr. 10 ; Assembly
mounting; adjust the assembly mounting .
– Remove supporting device .
– Install the left and right propeller shafts on the flange shafts on
the gearbox ⇒ Chassis, axles, steering; Rep. gr. 40 ; Propeller
shaft; remove and install propeller shaft .
– Remove heat shield for right drive shaft (if present) ⇒ Chassis,
axles, steering; Rep. gr. 40 ; Drive shaft; removing and in‐
stalling heat shield for drive shaft .
– Install assembly carrier ⇒ Chassis, axles, steering; Rep. gr.
40 ; Assembly carrier; Removing and installing assembly car‐
rier without steering gear.
– Install the front left and right wheelhouse liner ⇒ General body
repairs, exterior; Rep. gr. 66 ; Wheelhouse liner; removing and
– Carefully remove gearbox oil cooler screen -1-, then clean and
re-install.
– Connect the coolant hoses to the gearbox oil cooler and se‐
cure with clamps -arrows-.
– Remove hose clamps - MP7-602 (3094)- -A-.
NOTICE
tronics - J743- .
tronics.

– Carefully connect the connector -1- up to the stop and lock the
cap by turning it to the right (in -direction of arrow-).
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Re‐
moving and installing starter .
Vehicles with 2.0 TFSI and 2.0 TDI CR engines
– Install charge air line ⇒ Rep. gr. 21 ; Charge air system;
Summary of components - charge air system .
ble”, page 95 .
– Check coolant level, top up if necessary ⇒ Engine; Rep. gr.
19 ; Cooling system/coolant; Draining and filling up coolant .
– Inspect gear oil level and top up if necessary
– Install the front wheels ⇒ Chassis, axles, steering; Rep. gr.
44 ; Wheels, tyres .
– Install the engine cover panel ⇒ Rep. gr. 10 ; Engine cover
panel; Remove and install engine cover panel .
Note

♦ Gearbox to engine
♦ Gearbox console to gearbox
⇒ “5 Assembly bracket”, page 215
4.3.2 Installing the gearbox, vehicles with all-

wheel drive


• After the installation of the new mechatronics, the basic setting

• Replace needle bearing -arrow- in the crankshaft ⇒ Rep. gr.
13 ; Crankshaft; replace needle bearing in the crankshaft .
• Install angular gear (if this has been removed)
⇒ “2.3 Install angle gearbox”, page 43 .
• Lubricate the bolt and serration lightly with correct high-tem‐
perature grease ⇒ Electronic Catalogue of Original Parts .
• Check whether the dowel sleeves -A- for centering the gear‐
box are present in the cylinder block, insert if necessary.
• Check that the intermediate plate is seated correctly between
engine and gearbox.
moved.
• Use new screws which must be tightened to a torque angle as
well as sealing rings and seals.
• Secure all hose connections with hose clamps which comply
with the series design ⇒ Electronic Catalogue of Original
Parts .
– Carefully raise gearbox with engine/gearbox jack and bring it
to its installation position using the spindles of the gearbox
mount - 3282- .
• The engine and gearbox must be in line.
• Slide in the engine and gearbox by hand until the engine flange
and the gearbox flange are in contact.
• If necessary, you can turn the crankshaft.
• Do no trap any lines when inserting the gearbox.
– Screw on gearbox to the engine
⇒ “4.1 Tightening torques for gearbox”, page 106 .
– Remove the gearbox mount - 3282- from the gearbox.
– Evenly lift up the gearbox via the hooks of the supporting de‐
vice to the supporting arm of the gearbox mount.
NOTICE
Risk of damage to thread for gearbox console.
– Before screwing in the screws, the gearbox console and
supporting arm of the gearbox mount must be completely
parallel to each other.

– Insert new bolts -arrows- for gearbox mount and tighten at first
by hand.
– Adjust the engine/gearbox unit ⇒ Rep. gr. 10 ; Assembly
mounting; adjust the assembly mounting .
– Remove supporting device .
– Fit propshaft to angle gearbox ⇒ Propshaft and rear final drive;
Rep. gr. 39 ; Propshaft; remove and install propshaft .
• When fitting the propshaft, make sure that the sealing ring
-arrow- in the centring sleeve is not damaged.
• In case of damaged sealing ring the propshaft must be re‐
placed.
• Install all parts of the propshaft and flange of the angle gearbox
marked relative to each other in the same position.
– Install the left and right propeller shafts on the flange shafts on
the gearbox ⇒ Chassis, axles, steering; Rep. gr. 40 ; Propeller
shaft; remove and install propeller shaft .
shield for drive shaft .
– Install assembly carrier ⇒ Chassis, axles, steering; Rep. gr.
40 ; Assembly carrier; Removing and installing assembly car‐
rier without steering gear.
– Install the front left and right wheelhouse liner ⇒ General body
repairs, exterior; Rep. gr. 66 ; Wheelhouse liner; removing and
– Carefully remove gearbox oil cooler screen -1-, then clean and
re-install.

– Connect the coolant hoses to the gearbox oil cooler and se‐
cure with clamps -arrows-.
– Remove hose clamps - MP7-602 (3094)- -A-.
NOTICE
tronics - J743- .
tronics.
– Carefully connect the connector -1- up to the stop and lock the
cap by turning it to the right (in -direction of arrow-).
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Re‐
moving and installing starter .
Vehicles with 2.0 TFSI and 2.0 TDI CR engines
– Install charge air line ⇒ Rep. gr. 21 ; Charge air system;
Summary of components - charge air system .
ble”, page 95 .
– Inspect gear oil level and top up if necessary
– Install the front wheels ⇒ Chassis, axles, steering; Rep. gr.
44 ; Wheels, tyres .
– Install the engine cover panel ⇒ Rep. gr. 10 ; Engine cover
panel; Remove and install engine cover panel .
– After the installation of the new mechatronics, the basic setting
Note

♦ Gearbox to engine
♦ Gearbox console to gearbox
⇒ “5 Assembly bracket”, page 215

5 Assembly bracket
⇒ “5.1 Assembly overview - assembly mountings”, page 215
5.1 Assembly overview - assembly mountings
1 - Screw
❑ ⇒ Rep. gr. 10 ; Power‐
train mounting; Assem‐
bly overview - power‐
train mounting .
2 - Engine mounting
❑ with supporting arm
❑ removing and installing
⇒ Rep. gr. 10 ; Assem‐
bly mountings; installing
and removing engine
bracket
3 - Screw
train mounting .
4 - Screw
train mounting .
5 - Screw
train mounting .
6 - Screw
train mounting .
7 - Screw
train mounting; Assembly overview - powertrain mounting .
8 - Pendulum support
❑ removing and installing ⇒ Rep. gr. 10 ; Assembly mountings; installing and removing pendulum support
9 - Screw
❑ ⇒ Rep. gr. 10 ; Powertrain mounting; Assembly overview - powertrain mounting .
10 - Screw
11 - Screw
❑ Gearbox mount to gearbox
❑ 60 Nm + 90°
12 - Screw
5. Assembly bracket 215

13 - Gearbox mount
❑ removing and installing ⇒ Rep. gr. 10 ; Assembly mountings; installing and removing gearbox mount

6 Transporting the gearbox

♦ Lifting device - MP9-201 (2024A)-
♦ Workshop crane , e.g. -VAS 6100-
• The gearbox is filled with oil. Therefore, do not turn the gear‐
box so that the breather is underneath when transporting,
otherwise there is a risk of oil escaping.
If necessary, the cover of the breather can be removed and the
opening can be closed with a suitable screw plug.
– Attach the lifting device for engine - MP9-201 (2024A)- -A- to
– Hook the lifting device for engine - MP9-201 (2024A)- with

gearbox attached to workshop crane , e.g -VAS 6100- .
6. Transporting the gearbox 217

7 Attachment at engine and gearbox

mount
Attachment at engine and gearbox mount
♦ Bracket - VW 313- or -VAS 6095- or -VAS 6095A-
♦ Gearbox mount - T30109 (VW353)-
♦ Adapter - VW 309A-
The gearbox is filled with oil, so do not to turn the gearbox so that
the breather is underneath when transporting or on the assembly
support. Oil may escape from the gearbox in this position.
• If the gearbox filled with oil is turned on the assembly stand,
first pull off the breather and close the opening with an oil-tight
screw plug.
CAUTION
The centre of gravity of the gearbox is outside the turning centre
on the assembly stand .
Risk of injury if turned unintentionally.
– For turning the gearbox, a second mechanic must hold the
gearbox housing in order to avoid unintended turning.
– Secure the gearbox to the assembly stand, as shown in the

figure.
A - Gearbox mount - T30109 (VW353)-
B - Adapter - VW 309A-
C - Bracket - VW 313- or -VAS 6095- or -VAS 6095A-
Securing the angle gearbox or front axle differential lock engine
and gearbox mount

♦ Gearbox mount - T10108-
CAUTION
The centre of gravity of the gearbox is outside the turning centre
on the assembly stand .
Risk of injury if turned unintentionally.
– For turning the gearbox, a second mechanic must hold the
gearbox housing in order to avoid unintended turning.
Angular gearbox, differential lock for front axle is filled with oil, if
required. Therefore, do not turn the differential lock downwards
with the breather if required during transport and on the mounting
block. Oil may escape from the gearbox or different lock in this
position.
• If the gearbox filled with oil is turned on the assembly stand,
first pull off the breather and close the opening with an oil-tight
screw plug.

– Place the angle gearbox on the opening marked with number

“4” -arrow- in the gearbox bracket - T10108- with bracket - VW
313- or -VAS 6095- or -VAS 6095A- .
• Place nut M12 x 10 -pos. A- between angle gearbox and gear‐
box mount.
– Then align the angle gearbox with the 3 remaining openings
and secure with inserted nuts -A-.
7. Attachment at engine and gearbox mount 219

8 Transmission fluid circuit

⇒ “8.1 Summary of components - gear oil circuit”, page 220
⇒ “8.2 Removing and installing gearbox oil cooler”, page 221
⇒ “8.3 Removing and installing auxiliary hydraulic pump 1 for gear
oil V475 ”, page 222
⇒ “8.4 Remove and install the gear oil filter”, page 224
8.1 Summary of components - gear oil circuit
1 - Cover caps for gearbox

bleeder
2 - Sealing ring
❑ for gearbox oil cooler
3 - Screw
❑ 15 Nm + 60°
4 - Gearbox oil cooler
stalling gearbox oil cool‐
er”, page 221
5 - Gearbox
⇒ “4 Removing and in‐
stalling the gearbox”,
page 106
6 - Screw
❑ 8 Nm + 45°
7 - Motor for auxiliary hydraulic
pump 1 for gear oil - V475-
stalling auxiliary hy‐
draulic pump 1 for gear
oil V475 ”, page 222
8 - Sealing ring
9 - Gearbox oil filter
❑ Instructions for chang‐
ing oil and filter
⇒ page 8
❑ Removing and installing ⇒ “8.4 Remove and install the gear oil filter”, page 224
10 - Sealing ring
❑ insert with gear oil
11 - Oil filter housing for gearbox
❑ 50 Nm
12 - Heat shield
❑ for gear oil filter

8.2 Removing and installing gearbox oil

cooler
♦ Hose clamp - MP7-602 (3094)-
Removing
CAUTION
Risk of scalding from hot coolant
– When the engine is warm, the cooling system is under over‐
pressure, so there is a risk of scalding from hot steam and
hot coolant.
– Cover the cap on the coolant expansion tank with a cloth and
open carefully to release the excess pressure from the sys‐
tem.
– Wear protective spectacles and protective gloves.
– Place a sufficient quantity of lint-free textiles on gear oil cooler

and gearbox to catch escaping coolant.
– Close the coolant hoses with the hose clamps - MP7-602
(3094)- -A-.
– Remove clamps -arrow- and disconnect the coolant hoses
from the gearbox oil cooler -1-.
– Seal open lines with a clean plug e.g. from the plug set - VAS
6122- .
• There must be no coolant on the gearbox.
– Screw out the screws -arrows- and remove the gearbox oil
cooler -1-.
Installing
Installation is carried out in the reverse order; pay attention to the
following points:
8. Transmission fluid circuit 221

• Before installing, replace sealing rings -arrows-.

• Moisten sealing rings with gear oil before inserting.
• If the sealing surface on the gearbox oil cooler is damaged,
the cooler must be replaced.
• When installing the original gearbox oil cooler, carefully re‐
move the screen -1-, then clean and re-install.
– Carefully fit the gearbox oil cooler -1-, taking note of the sealing
rings.
– Screw in and tighten screws -arrows- one after the other cross‐
wise.
– Check gear oil level
– Install air filter ⇒ Rep. gr. 23 ; Air filter; Removing and instal‐
ling air filter housing .
Note

♦ Gearbox oil cooler to gearbox

⇒ “8.1 Summary of components - gear oil circuit”, page 220
8.3 Removing and installing auxiliary hy‐

draulic pump 1 for gear oil - V475-

Removing
Vehicles with four-wheel drive
– Remove angle gearbox
⇒ “2.2 Remove angle gearbox”, page 36 .
– Unlock lock -a- and disconnect connector for -b- auxiliary hy‐
draulic pump 1 for gear oil - V475- .
– Unscrew securing bolts -arrows-.

Shown on gearbox removed from vehicle.
– Insert extractor tool - T10530- into the bolt hole and then turn
nut -2- clockwise until the extractor tool is clamped.
– Carefully pull out the motor for auxiliary hydraulic pump 1 for
gear oil - V475- using the extractor tool - T10530- .
Installing
• Wet the sealing ring with gear oil before installing the pump.
– Push motor for auxiliary hydraulic pump 1 for gear oil - V475-
evenly into the gearbox housing by hand.

– Bolt on pump with new bolts -arrow- and tighten bolts cross‐
wise in stages.
⇒ “9.4 Draining and filling gearbox oil”, page 231
Vehicles with four-wheel drive
– Install angle gearbox ⇒ “2.3 Install angle gearbox”, page 43
Note

♦ ⇒ “8.1 Summary of components - gear oil circuit”, page 220
8.4 Remove and install the gear oil filter

When changing the gear oil, the gearbox oil filter must not always
be replaced.
• Therefore follow the instructions for when the gearbox oil filter
must be replaced and when not ⇒ page 8 .
A residual amount of gear oil is left in the oil filter. The gear oil
flows out when the oil filter housing is unscrewed.
• Before detaching the oil filter housing for gearbox, cover the
area around the filter with enough lint-free cloths.
• Thoroughly clean all points that may be reached by the gear
oil that flows out.
– Remove heat protection from oil filter for gearbox -1-.
– Detach and screw out oil filter housing for gearbox and remove
oil filter element.
Installing
• Replace the sealing rings for the oil filter housing and moisten
with gear oil before assembly.
• Replace missing or damaged heat protection for oil filter hous‐
ing.

– Insert oil filter element with suction belt -arrow- into the gear‐
box.
– Insert oil filter housing and tighten, then fit heat shield.
– Install air filter ⇒ Rep. gr. 23 ; Air filter; Removing and instal‐
ling air filter housing .
Note

♦ ⇒ “8.1 Summary of components - gear oil circuit”, page 220

9 Gear oil
screws”, page 226
⇒ “9.2 Tools needed for changing the gear oil”, page 226
⇒ “9.3 Checking the gear oil level”, page 227
9.1 Summary of components - oil drain plugs and check screws
1 - Overflow pipe
❑ Pay attention to the in‐
structions for the over‐
flow pipe and different
variants ⇒ page 9
❑ 3 Nm
2 - Sealing ring
3 - Drain plug
❑ for gear oil
❑ 45 Nm
4 - Drain plug for mechatronics
❑ 10 Nm + 45°
9.2 Tools needed for changing the gear oil

♦ Adapter for oil filling - VAS 6262A-
♦ Adapter - VAS 6262/6- or adapter - VAS 6262/7-
♦ Old oil collecting and suction equipment , e.g. -VAS 6622A-
♦ Vehicle diagnosis tester
♦ Protective goggles

♦ Acid-resistant gloves
• Only spare part gear oil should be used for the dual clutch
gearbox “0GC” ⇒ Electronic Catalogue of Original Parts .
• If the thread of the oil bottle does not match the oil filling adapt‐
er - VAS 6262A- , the adapter - VAS 6262/6- or adapter - VAS
6262/7- must be used in addition.
Work on the oil filling adapter - VAS 6262A- hose.
• The pipe of the oil filling adapter - VAS 6262A- must be short‐
ened to prevent it colliding with the bottom of some oil bottles.
Shorten the pipe of the adapter for oil filling - VAS 6262A-
Dimension -a- is measured from the shaft (green area in the fig‐
ure) of the oil filling adapter .
Dimension -a- = 210 mm.
– Shorten the tube of the adapter to dimension -a-.
9.3 Checking the gear oil level

♦ Adapter - VAS 6262/6- or adapter - VAS 6262/7-
9. Gear oil 227


Test conditions
• Observe rules for cleanliness
• Vehicle on completely level ground.
• The gearbox is not in the emergency running mode.
• Selector lever in “P” position, handbrake activated.
• The air conditioning and heating systems are switched off.
• The engine is running at idling speed.
CAUTION
Risk of accident
The radiator fan may run automatically.
– When working close to the radiator, keep sufficient distance
from the fan.
Checking the gear oil level

The gear oil level changes with the gearbox oil temperature.
The gearbox is not filled correctly if the gearbox oil temperature
is too low or too high.
The gearbox function is impaired if the gear oil level is too high or
too low.
• The gear oil temperature must be approx. 30°C when starting
work.
– Connect ⇒ Vehicle diagnostic tester and identify the vehicle
with Guided Functions .
– Select the dual-clutch gearbox .
– Select check oil level .
• The target temperature at the start of the test may not exceed
30°C, otherwise, the gearbox must be allowed to cool down.
CAUTION
Risk of injury from hot gear oil.
– Place the waste oil collection and extraction unit such as -VAS
6622A- drip tray underneath the gearbox, if required.
• The engine is running at idling speed.

– Remove oil drain plug -arrow-.
• Built up gear oil flows out of the overflow pipe -arrow 2-.
When you open the drain plug -arrow 1-, a small amount of gear
oil always flows out, regardless of the gear oil level.
NOTICE
There are different versions of overflow pipe.
Insufficient oil quantity and overfilling the oil impairs the function
of the individual parts of the gearbox and may cause damage.
– Check which overflow pipe is installed and carry out the oil
level check right after the workshop process.
Gearbox with beige overflow pipe
NOTICE
The gearbox is damaged if overfilled.
– The correct oil level is below the level of the overflow pipe.
– You must therefore unscrew the overflow pipe by 2 turns to
check and correctly adjust the oil level.
– Loosen overflow pipe by 2 turns.

Gearbox with red overflow pipe
• Unscrewing the overflow pipe to check the oil level is not re‐
quired.
Continued for all versions
• If a small quantity of oil still runs out at temperatures of 35 - 45
°C (oil starts to drip), the gearbox oil level is OK.
A small amount of oil comes out of the overflow pipe every 30
seconds, regardless of the oil level. This is caused by pulsation
in the cooling oil for the coupling.
Such escaping oil do not indicated whether the gear oil level is
adequate, so they must not be taken into account when deter‐
mining the oil level.
• If no oil escapes when checking, top up oil ⇒ page 230 .
• If the oil level is OK.
– Tighten overflow pipe, as per the instructions ⇒ page 9 .
9. Gear oil 229

– Screw in and tighten oil drain plug -arrow- with new seal.
Top up with gearbox oil
NOTICE
• Only spare part gear oil should be used for the 7-speed
gearbox 0GC ⇒ Electronic Catalogue of Original Parts .
The adapter for oil filling must be clean and the gearbox oil must
not be mixed with other oils!
The oil that has escaped must not be used again.
For topping up, use adapter for oil filling - VAS 6262A- .
• Shake oil bottle well before opening to mix any sediments at
the bottom of the bottle with the oil.
er - VAS 6262A- , the adapter - VAS 6262/6- or adapter - VAS
6262/7- must be used in addition.
– Screw in the overflow pipe as far as it will go, paying attention
to the instructions ⇒ page 9 .
– Screw the gearbox oil bottle to the adapter for oil filling - VAS
6262A- .

– Screw the adapter for oil filling - VAS 6262A- -A- by hand into
the hole of the check and filler screw -arrow 1-.
– Hold the bottle with the adapter for oil filling - VAS 6262A- as
high as possible above the level of the gearbox and fill with 1
litre of gear oil.
– Disconnect the adapter for oil filling - VAS 6262A- from the
quick coupler and let excess gear oil drain off.
– Checking the gear oil level ⇒ page 228
• If no oil escapes through the opening:
– Fill up with another 1.0 litres of oil and repeat the procedure.
Note

♦ Oil drain plug to gearbox

screws”, page 226
9.4 Draining and filling gearbox oil

♦ Adapter - VAS 6262/6- or -VAS 6262/7-
NOTICE
Risk of damage to gearbox
– Do not run the engine or tow the vehicle when the cover for
mechatronics has been removed or without filling gear oil.
Conditions
• Observe rules for cleanliness
• Follow the instructions for the overflow tube ⇒ page 9 .
• Vehicle on completely level ground.
• Remove the sound dampening system ⇒ General body re‐
• Engine switched off.
• The gearbox is not in the emergency running mode.
9. Gear oil 231

CAUTION
Risk of accident
The radiator fan may run automatically.
– When working close to the radiator, keep sufficient distance
from the fan.
CAUTION
Risk of injury from hot gear oil.
Draining out gear oil

– Place the waste oil collection and extraction unit such as -VAS
6622A- drip tray underneath the gearbox, if required.
– Unscrew the check and filler screw -arrow-.
• Accumulated gear oil flows out of the overflow pipe.
– Unscrew the overflow pipe and let the gear oil drain out.
– Unscrew the oil drain plug for mechatronics -arrow-.

The remaining gear oil drains out.
Tip:
• Wait approx. 4 minutes until all the gear oil has leaked out.
– Screw in new drain plug for mechatronics.
Pour in gear oil
• Follow the instructions for the overflow tube ⇒ page 9 .

– Screw in overflow pipe -arrow-.
NOTICE
• Only spare part gear oil should be used for the 7-speed
gearbox 0GC ⇒ Electronic Catalogue of Original Parts .
The adapter for oil filling must be clean and the gearbox oil must
not be mixed with other oils!
For topping up, use adapter for oil filling - VAS 6262A- .
• The pipe of the adapter for oil filling - VAS 6262A- must be
shortened to prevent it colliding with the bottom of soil oil bot‐
tles ⇒ page 227 .
• Shake oil bottle well before opening to mix any sediments at
the bottom of the bottle with the oil.
er - VAS 6262A- , the adapter - VAS 6262/6- or -VAS 6262/7-
must be used in addition.
– Screw the gearbox oil bottle to the adapter for oil filling - VAS
6262A- .
9. Gear oil 233

– Screw the adapter for oil filling - VAS 6262A- -A- by hand into
the hole of the check and filler screw -arrow 1-.
– Hold the bottle with the adapter for oil filling - VAS 6262A- as
high as possible above the level of the gearbox and fill with 6
litres of gear oil.
To change the bottle, the shut-off valve can be sealed or the
adapter for oil filling - VAS 6262A- can be held higher than the
gearbox.
Note
The exact oil level is refilled during the oil level check.
• Selector lever in »P«.

– Start engine and run in idle.
– Depress the brake pedal and shift the selector lever to all po‐
sitions “P, R, N, D/S”, during which you should leave the
selector lever in each position for at least 3 seconds.
– Shift selector lever back into position “P”.
Note

♦ Oil drain plugs and overflow pipe to gearbox

screws”, page 226

35 – Gears, shafts
1 Disassemble and assemble wheels
and shafts
At present no repairs are carried out on the pinions and shafts.
1. Disassemble and assemble wheels and shafts 235

39 – Final drive - differential

1 Gear oil
⇒ “1.1 Checking the gear oil level”, page 236
1.1 Checking the gear oil level

⇒ “1.1.1 Inspecting gear oil in the angle gearbox”, page 236
1.1.1 Inspecting gear oil in the angle gearbox

♦ Catch pan
The angle gearbox has an automatic oil filling for final drives.
Oil specification for the angle gearbox ⇒ Electronic Catalogue of
Original Parts
Test conditions
• The vehicle must be completely level.
• Selector lever in “P”.
– Unscrew nuts and remove protection plate for right drive shaft
(if present).
– Place the catch pan under the gearbox.
CAUTION
Risk of injury from hot oil for final drives.
236 Rep. gr.39 - Final drive - differential

– Unscrew oil filler plug -1-.

• Oil level in angle gearbox should be at lower edge of oil filler
hole.
• Replace filler screw after disassembly.
• If oil gets onto the angle gearbox. it must be removed imme‐
diately.
If oil level is low:
– Fill angle gearbox with oil for final drives
– Screw in new oil filler plug for angle gearbox.
– Install protection plate for right drive shaft ⇒ Chassis, axles,
steering; Rep. gr. 40 ; Drive shaft; removing and installing
drive shaft heat shield .
Note

♦ Oil filling and drain plug for angle gearbox

⇒ “4.1 Assembly overview - angle gearbox parts”, page 247 .
1.2 Draining and filling gearbox oil

⇒ “1.2.1 Draining and filling gear oil in the angle gearbox”,
page 237
1.2.1 Draining and filling gear oil in the angle

gearbox
♦ Filling device - VAS 6291A-
♦ Adapter - VAS 6262/6- or -VAS 6262/7-
♦ Adapter for oil filling - VAS 6291/3-
♦ Catch pan
Oil needs to be drained from the angle gear only for repairs. Oil
is not replaced.
Oil specification for the angle gearbox ⇒ Electronic Catalogue of
Original Parts
Conditions
• The vehicle must be completely level.
• Selector lever in “P”.
1. Gear oil 237

Drain oil
– Remove protection plate for right drive shaft (if present)
-arrows- to provide better access to the filler screw.
CAUTION
Risk of injury from hot oil for final drives.
– Remove the oil drain plug -2- and let the gear oil drain off.
– Screw in new oil drain plug -2- and tighten.
Replenish oil
– Unscrew oil filler plug -1-.
– Screw in adapter for oil filling - VAS 6291/3- into the filler hole
as far as it will go.
– Attach angular piece of filling device - VAS 6291A- to adapter
for oil filling - VAS 6291/3- .
• The hose must not sag.

• Make sure that the valve of the filling device - VAS 6291A-
-arrow- is closed.
– Screw oil reservoir onto filling device - VAS 6291A- .
• On some oil bottles, the adapter - VAS 6262/6- or -VAS
6262/7- must be used.

– Open the valve -arrow- and hold the oil reservoir as high as
possible above the level of the gearbox.
• The angle gearbox is filled correctly when oil comes out at the
adapter for oil filling - VAS 6291/3- .
• If no oil flows out, continue the filling procedure.
– Remove adapter for oil filling - VAS 6291/3- .
– Screw in previous gearbox oil filler plug and tighten slightly.
– Start engine, engage a gear and allow gearbox to rotate for
about 2 minutes.
– Switch off engine and unscrew oil drain plug.
– Check the oil level.
• Set value: the oil level in the final drive must be at the lower
edge of oil filler hole.
• As needed, replenish oil for final drives up to lower edge of oil
filler hole.
• If oil gets onto the angle gearbox. it must be removed imme‐
diately.
– Install new oil filler plug.
shield for drive shaft .
Note

♦ Oil filling and drain plug for angle gearbox

⇒ “4.1 Assembly overview - angle gearbox parts”, page 247 .
1. Gear oil 239

2 Sealing rings
⇒ “2.1 Installation overview - sealing rings”, page 240
⇒ “2.2 Replacing left sealing ring”, page 240
⇒ “2.3 Replacing right sealing ring”, page 242
2.1 Installation overview - sealing rings
1 - Right sealing ring

❑ Replace
⇒ “2.3 Replacing right
sealing ring”, page 242
2 - Sealing ring for gearshift
shaft
❑ Replace
⇒ “3.11 Replacing the
sealing ring for the gear‐
shift shaft”, page 101
3 - Left sealing ring
❑ Replace
⇒ “2.2 Replacing left
sealing ring”, page 240
2.2 Replacing left sealing ring

♦ Thrust piece - T10457-
♦ Catch pan
♦ Commercially available drill
Removing
– Remove left drive shaft ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Drive shaft; Removing and installing drive shafts .

NOTICE
Risk of damage to the bearing when drilling
– Only drill through the metal plate ring of the radial shaft seal.
– Do not screw in the sheet metal screw too deep.
– Close the openings for the drive shaft with a clean cloth -2-.
– Grease drill -3- so that the swarf from drilling sticks to the drill.
– Carefully drill a hole with a diameter of 2-4 mm into the outer
metal plate -1- of the sealing ring.
– Screw a sheet metal screw with a diameter of approx. 4 mm

into the drilled hole of the seal.
• The sheet metal screw must not be screwed in too deep, so
that the bearing behind the screw is not damaged.
– Pull out the seal with the extractor - T10055- with adapter -
T10055/2- .
– Carefully pull the cloth out of the opening for the drive shaft.
• Dirt and swarf must not get into the gearbox.
• Thoroughly clean the gearbox and the opening for the drive
shaft.
• If you an only pull out the steel ring, carefully lever out the rest
of the seal with a screwdriver.
Installing
– Fill the space between the sealing lip and dust lip with sealing
grease for radial shaft seal - G 052 128 A1- -arrow- and mois‐
ten the outer circumference with gear oil.
• Fitting position: The open side of the sealing ring faces to‐
wards the gearbox.
– Fit seal ring by hand and press in as far as possible, so that
the seal is fixed in the gearbox housing.
2. Sealing rings 241

– Use the gasket ring with press-on sleeve - T10457- to drive

the gasket ring as far as it will go into the gearbox housing.
• Keep the sealing ring straight.
– Install left drive shaft ⇒ Chassis, axles, steering; Rep. gr. 40 ;
Drive shaft; removing and installing drive shaft .
– Check gear oil, top up if necessary
2.3 Replacing right sealing ring

⇒ “2.3.1 Replace sealing ring on right, vehicles with front drive”,
page 242
⇒ “2.3.2 Replacing right sealing ring, vehicles with four-wheel
drive”, page 243
2.3.1 Replace sealing ring on right, vehicles

with front drive
♦ Catch pan
♦ Commercially available drill
Removing
The gearbox is installed.
– Install right drive shaft ⇒ Chassis, axles, steering; Rep. gr.
40 ; Drive shaft; removing and installing drive shaft .
NOTICE
Risk of damage to the bearing when drilling
– Only drill through the metal plate ring of the radial shaft seal.
– Do not screw in the sheet metal screw too deep.
– Close the openings for the drive shaft with a clean cloth -2-.
– Grease drill -3- so that the swarf from drilling sticks to the drill.
– Carefully drill a hole with a diameter of 2-4 mm into the outer
metal plate -1- of the sealing ring.
– Screw a sheet metal screw with a diameter of approx. 4 mm
into the drilled hole of the seal.
• The sheet metal screw must not be screwed in too deep, so
that the bearing behind the screw is not damaged.

– Pull out the seal with the extractor - T10055- with adapter -
T10055/2- .
– Carefully pull the cloth out of the opening for the drive shaft.
• Dirt and swarf must not get into the gearbox.
• Thoroughly clean the gearbox and the opening for the drive
shaft.
• If you an only pull out the steel ring, carefully lever out the rest
of the seal with a screwdriver.
Installing
• Fitting position: The open side of the sealing ring faces to‐
wards the gearbox.
– Fit seal ring by hand and press in as far as possible, so that
the seal is fixed in the gearbox housing.
– Use the gasket ring with press-on sleeve - T40372- to drive

the gasket ring as far as it will go into the gearbox housing.
• Keep the sealing ring straight.
– Install left drive shaft ⇒ Chassis, axles, steering; Rep. gr. 40 ;
Drive shaft; removing and installing drive shaft .
– Check gear oil, top up if necessary
2.3.2 Replacing right sealing ring, vehicles

with four-wheel drive
♦ Catch pan
2. Sealing rings 243

– Lever out the sealing ring on the gearbox with extractor hook
- T20143/1- or - T20143/2- -A-.
– Drive in new sealing ring with thrust piece - T10049- up to the

stop.
• Keep the new sealing ring straight.
– Install angle gearbox ⇒ “2.3 Install angle gearbox”, page 43 .

3 Differential
⇒ “3.1 Removing and installing right flange shaft”, page 245
3.1 Removing and installing right flange

shaft
⇒ “3.1.1 Removing and installing right flange shaft, vehicles with
four-wheel drive”, page 245
3.1.1 Removing and installing right flange

shaft, vehicles with four-wheel drive
♦ Catch pan
Removing
• The gearbox is installed.
shaft.
- T10107A- .
• To loosen the bolt for the flange shaft, insert 2 bolts into the
flange and counterhold the flange shaft with am assembly lev‐
er.
3. Differential 245
– Screw on the extractor device - T10037- to the right flange

shaft as shown.
– Align extractor - T10037- with the knurled nut - T10037/1- and
the moving screw -A- parallel to the flange.
– Take out the flange shaft.
Installing
– Drive in the flange shaft carefully while rotating at the same
time.
– Screw on the flange shaft.
– Install right drive shaft ⇒ Chassis, axles, steering; Rep. gr.
40 ; Drive shaft; removing and installing drive shaft .
– Inspecting oil level in the angle gearbox
Note


Screw for right flange shaft 25 Nm

4 Bevel gear components

⇒ “4.1 Assembly overview - angle gearbox parts”, page 247
⇒ “4.2 Dismantling and assembling the bevel gear”, page 252
⇒ “4.3 Replacing gasket rings for angle gearboxes”, page 266
⇒ “4.4 Replacing the right flange shaft needle bearing”,
page 268
4.1 Assembly overview - angle gearbox

parts
⇒ “4.1.1 Summary of components - parts of angle gearbox 0CN”,
page 247
⇒ “4.1.2 Summary of components - parts of angle gearbox 0FN”,
page 249
⇒ “4.1.3 Summary of components - parts of angle gearbox 0AV”,
page 251
4.1.1 Summary of components - parts of angle gearbox 0CN
1 - Sealing ring
❑ on gearbox side
❑ Replace
⇒ “4.3.2 Replacing the
sealing ring for the angle
gearbox - Gearbox
side”, page 267
2 - Angle gearboxes 0CN
❑ Designation and distinc‐
tion
gearbox”, page 4
❑ Summary of compo‐
nents
⇒ “2.1 Summary of com‐
ponents - angle gear‐
box”, page 35
❑ removing
gearbox”, page 36
❑ installing
box”, page 43
3 - Oil drain plug
❑ with captive sealing ring
❑ 20 Nm
4 - Oil filler plug
❑ 20 Nm
5 - Sealing ring
❑ for right flange shaft
❑ Replace ⇒ “4.3.1 Replacing sealing ring for angle gearboxes - on flange shaft side”, page 266
4. Bevel gear components 247

6 - Ventilation tube
❑ Angle gearbox ventilation
❑ pull in up to stop
7 - Cap
8 - Right flange shaft
⇒ “3.1.1 Removing and installing right flange shaft, vehicles with four-wheel drive”, page 245
9 - Sealing ring
❑ insert into the round slot of the right flange shaft
❑ remove when replacing the needle bearing (Pos. 10)
10 - Needle bearing
❑ Replace ⇒ “4.4 Replacing the right flange shaft needle bearing”, page 268
11 - Circlip
12 - Twelve-point nut
❑ secure by caulking after tightening ⇒ page 258
❑ 340 Nm
13 - Angle gearbox output flange
❑ Removing and installing ⇒ “4.2.1 Remove output flange, Angle gearboxes 0CN”, page 252
14 - Adjusting washer
❑ not available as spare part
15 - Sealing ring
❑ for angle gearbox output flange
❑ Replace ⇒ “4.2.1 Remove output flange, Angle gearboxes 0CN”, page 252
16 - Inner ring/tapered-roller bearing
17 - Screw
❑ 7 pieces
❑ Tighten in small stages crosswise
❑ 38 Nm
18 - Pinion housing
❑ with shaft bevel gear and outer ring/ tapered-roller bearing
❑ Removing and installing ⇒ “4.2.1 Remove output flange, Angle gearboxes 0CN”, page 252
❑ Note screw holes; drive pinion housing will only fit in one position
19 - O-ring
❑ To replace, unscrew the screws -pos. 17- and carefully lever out the drive pinion housing from its recess
in the pinion housing
❑ Do not remove the 12-point nut -pos. 12- and the output flange -pos. 13-
❑ Note screw holes of the angle gearbox. the adjusting washer will only fit in one position
21 - Screw cap

4.1.2 Summary of components - parts of angle gearbox 0FN
1 - Circlip
2 - Surface
3 - Output flange
⇒ “4.2.2 Remove output
flange, Angle gearbox‐
es 0FN”, page 259
4 - Sealing ring
❑ Replace
es 0FN”, page 259
5 - O-ring
❑ Replace
es 0FN”, page 259
6 - Cover
❑ not available as spare
part
7 - O-ring
❑ Replace
es 0FN”, page 259
8 - Bearings
❑ not available as spare
part
10 - Drive pinion
12 - Bearings
13 - Sealing ring
❑ Replace ⇒ “4.3.2 Replacing the sealing ring for the angle gearbox - Gearbox side”, page 267
14 - Cap
15 - Angle gearboxes 0FN
❑ Designation and identification of the angle gearboxes ⇒ “2.2 Marking angle gearbox”, page 4
❑ removing ⇒ “2.2 Remove angle gearbox”, page 36
❑ installing ⇒ “2.3 Install angle gearbox”, page 43

16 - Breather
17 - Ventilation flap
18 - Sealing ring
❑ Replace ⇒ “4.3.1 Replacing sealing ring for angle gearboxes - on flange shaft side”, page 266
19 - Circlip
20 - Needle bearing
21 - Needle bearing
22 - Sealing ring
23 - Flange shaft
24 - Oil filler plug
❑ with sealing ring
❑ 20 Nm
25 - Oil drain plug
❑ with sealing ring
❑ 20 Nm
26 - Screw
❑ 6 pieces
❑ gradually tighten crosswise
❑ 38 Nm

4.1.3 Summary of components - parts of angle gearbox 0AV
1 - Sealing ring
❑ Left on gearbox side
❑ Replace
⇒ “4.3.2 Replacing the
sealing ring for the angle
gearbox - Gearbox
side”, page 267
2 - Angle gearboxes 0AV
❑ Designation and identi‐
fication of the angle
gearboxes
gearbox”, page 4
❑ removing
gearbox”, page 36
❑ installing
box”, page 43
3 - Oil drain plug
❑ 15 Nm
4 - Sealing ring
❑ Right on the flange shaft
side
❑ Replace
⇒ “4.3.1 Replacing seal‐
ing ring for angle gear‐
boxes - on flange shaft
side”, page 266
5 - Oil filler plug
❑ 15 Nm
6 - Ventilation tube
7 - Cap
8 - Right flange shaft
9 - Sealing ring
❑ insert into the round slot of the right flange shaft
❑ remove when replacing the needle bearing (Pos. 10)
10 - Needle bearing
11 - Circlip

12 - Nut
❑ Mounting for output flange
❑ Use securing means - D 000 600-
❑ 480 Nm
13 - Output flange
❑ Removing and installing ⇒ “4.2.3 Remove output flange, Angle gearboxes 0AV”, page 262
14 - Cover cap for output flange
❑ replace if damaged
16 - Sealing ring
❑ for output flange
❑ Replace ⇒ “4.2.3 Remove output flange, Angle gearboxes 0AV”, page 262
17 - Inner ring/tapered-roller bearing
18 - Screw
❑ 7 pieces
❑ Tighten in small stages crosswise
❑ 25 Nm
19 - Pinion housing
❑ with shaft bevel gear and outer ring/ tapered-roller bearing
❑ Removing and installing ⇒ “4.2.3 Remove output flange, Angle gearboxes 0AV”, page 262
❑ Note screw holes; the drive pinion housing will only fit in one position
20 - O-ring
❑ To replace, remove the drive pinion housing (item 19)
❑ Note screw holes of the angle gearbox. the adjusting washer will only fit in one position
22 - Screw cap
4.2 Dismantling and assembling the bevel

gear
⇒ “4.2.1 Remove output flange, Angle gearboxes 0CN”,
page 252
⇒ “4.2.2 Remove output flange, Angle gearboxes 0FN”,
page 259
⇒ “4.2.3 Remove output flange, Angle gearboxes 0AV”,
page 262
4.2.1 Remove output flange, Angle gearbox‐

es 0CN
♦ Mounting bracket - T10108/1-

♦ Socket insert SW 34
♦ Alignment rails - MP3-457 (VW 457)-
♦ Pressure spindle - MP3-423 (VW 407)-
♦ Tapered-roller bearing extractor - V.A.G 1582-
♦ Gripper - V.A.G 1582/13-
♦ Thrust plate - MP3-467 (40-105)-
♦ Pressure plate - MP3-407 (VW 402)-
♦ Retractor - T30070 (VW 204B)-
♦ Pipe section - T30055 (3296)-
♦ Thrust piece - MP3-411 (VW 454)-
♦ Press-on sleeve - MP3-412 (VW 455)-
♦ Dial gauge
♦ Sealing grease ⇒ Electronic Catalogue of Original Parts
♦ Screw M10 × 30 - 2 pcs
♦ Screw M8 x 25 - 1 pc
♦ Nut M12 x 10 - 4 pcs
Designation and identification of the angle gearboxes
The inner ring/tapered-roller bearing is pressed onto the output
flange of the angle gearbox.
This will be removed later in the workflow.
Do not replace the tapered-roller bearing for the angle gearbox
output flange and the shims!
Removing
– Position angle gearbox onto the opening -arrow- marked with
the number “4” in the gearbox mount - T10108- .
box mount.
– Drain oil from the angle gearbox

– Drive out caulkings -arrows- of the twelve-point nut -A- from

the grooves of the output flange -B-.
– Lock output flange of angle gearbox with bracket - T10108/1-

that is attached with 2 screws M10 x 30 -arrows-.
A - Socket insert SW 34
– Unscrew nut for output flange.
– Pivot angle gearbox so that the output flange is facing up.

– Unscrew screws -arrows- for drive pinion housing -A-.
– Using a suitable screwdriver -B-, lever out the pinion housing

with the output flange and bevel gear one after the other in the
region of the three recesses -arrows-.

– Place output flange -A- uniformly on the alignment rails -

MP3-457 (VW 457)- -arrows-.
B - Alignment rails - MP3-457 (VW 457)-
C - Pressure spindle - MP3-423 (VW 407)-
– Push shaft bevel gear out from the output flange -A-.
• Secure shaft bevel gear and inner ring/tapered-roller bearing
against falling.
– Push output flange -A- out from the drive pinion housing.
B - Alignment rails - MP3-457 (VW 457)-
C - Pressure spindle - MP3-423 (VW 407)-
• Sealing ring -arrow- is located on the output flange.
NOTICE
Risk of damage to the inner ring/tapered-roller bearing.
If the inner ring/tapered-roller bearing is damaged, the angle
gearbox must be replaced.
• Inner ring/tapered-roller bearing must be pulled off the output

flange to remove the sealing ring.
– Pull off inner ring/tapered-roller bearing with gripper - V.A.G
1582/13- .
– Place pressure plate - MP3-467 (40-105)- on the output
flange.
– Pull off inner ring/tapered-roller bearing with tapered-roller
bearing extractor from output flange.
– Remove sealing ring from output flange.
Installing

– Put the existing inner ring/tapered-roller bearing -1- into the

drive pinion housing.
– Lightly oil the new sealing ring -2- for output flange around the
outer circumference.
– Press in sealing ring until flush.

1 - Pressure plate - MP3-407 (VW 402)-
2 - Pressure spindle - MP3-408 (VW 412)-
3 - Retractor - T30070 (VW 204B)-
• The large diameter of the retractor - T30070 (VW 204B)- points
towards the sealing ring.
– Fill half the space between the sealing lip and dust lip with
sealing grease ⇒ Electronic catalogue of original parts .
– Push inner ring/tapered-roller bearing ⇒ page 256 onto the

output flange until it stops.
1 - Pressure plate - MP3-407 (VW 402)-
2 - Pipe - T30055 (3296)-
3 - Pressure spindle - MP3-408 (VW 412)-
4 - Thrust piece - MP3-411 (VW 454)-
• The large diameter of the thrust piece - MP3-411 (VW 454)-
points towards the output flange.
• Press on inner ring/tapered-roller bearing until it stops. Do not
apply a large pressing force to the tapered-roller bearing.
– Fit the adjusting washer -2-, inner ring/tapered-roller bearing

-3- and pinion housing -4- to the shaft bevel gear -1-.
• Reinstall the previous shim -2-. This ensures the bearing pre‐
load of the shaft bevel gear in the pinion carrier.

– Gently press drive pinion housing with output flange onto the
shaft bevel gear up to the stop.
A - Press-on sleeve - MP3-412 (VW 455)-
B - Pressure spindle - MP3-408 (VW 412)-
C - Thrust piece - MP3-411 (VW 454)-
D - Pressure plate - MP3-407 (VW 402)-
• The shoulder -arrow- of the insertion bushing - MP3-412 (VW
455)- points to the shaft bevel gear.
• Rotate the drive pinion housing while pressing it on.
– Align the previous shim -3- opposite the drive pinion housing
-2-.
• Drive pinion housing -2- and shim -3- only fit in one position.
– Moisten new O-ring -1- with oil for final drives and fit onto drive
pinion housing -2-.
– Insert drive pinion housing -2- into angle gearbox housing
-4-.
• The teeth of the shaft bevel gear must be engaged with the
head.
• Align the screw holes for drive pinion housing opposite the
angle gearbox housing.
– Tighten screws -1- in small increments alternately on opposite

sides. while rotating the output flange -2- slightly back and
forth in the -direction of the arrow-.
– Tighten screws -arrows- for drive pinion housing -A- cross‐

wise.

– Tighten new 12-point nut for output flange

⇒ Item 12 (page 248) .
A - Insertion tool SW 34
Secure new 12-point nut for output flange:

– Caulk 12-point nut -A- at 120° offset in the grooves of the out‐
put flange -B- -arrows-.
• After tightening the nut for the output flange, check the runout
on fixing bolt of the shaft bevel gear.
Measure the runout on the output flange of the shaft bevel gear
A - Universal dial gauge bracket - MP3-447 (VW 387)-
B - Screw M8 x 25
C - Dial gauge
– Fasten a universal dial gauge holder -A- with M8 x 25 bolt
-B- on the angle gearbox.
– Position the dial gauge -C- on the fixing bolt of the shaft bevel
gear -D-.
– Set the dial gauge to “0” with 1 mm bias.
– Rotate output flange one full turn -arrow-.
– Read measured value on the dial gauge.
• Runout: maximum 0.05 mm
– Fill angle gearbox with oil
Note

♦ ⇒ “4.1.1 Summary of components - parts of angle gearbox

0CN”, page 247


es 0FN
♦ Three-arm extractor e. g. -VAS 251 205- or -Kukko 45-2-
♦ Counterholder - T40265-
♦ Thrust piece - MP3-427 (40-21)-
♦ Nut M12 x 10 - 4 pcs
Removing
box mount.
– Turn angle gearbox such that output flange is facing up.
– Remove circlip -1- and take out base -2-.

– Extract output flange with three-arm extractor -A- from the

bevel gear of the angle gearbox.
A - Three-arm extractor e. g. -VAS 251 205- or -Kukko 45-2-
• Replace sealing ring -1- and O-ring -2-.
– Pull out sealing ring -A- with extractor tool - T20143/1- .

• The seat of the sealing ring in the housing must not be dam‐
aged.
– Clean residues of the sealing compound from the area on the
shaft bevel gear.
– Remove using ring tool - T40265- the O-ring -A- from the shaft.

Installing
– Position the new O-ring -arrow- onto the shaft.
• The O-ring must be located behind the gear teeth, in the base
of the circumferential groove -arrow-.
– Lightly wet external circumference of the radial shaft seal ring

-1- with gear oil.
• Fill half the space between the sealing lip and dust lip with
sealing grease - G 052 128 A1- .
– Drive in sealing ring with pressure plate - T40121- up to the

stop.
– Drive output flange -A- all the way with plastic hammer care‐
fully onto the shaft.
A - Gearbox mount - T10108-
B - Drive bushing - MP3-427 (40-21)-
C - Angle gearbox output flange

– Use disc -A-.

– Secure output flange with locking ring -B-.
Locking ring -B- has a rough profile -Arrow 1-.
• Locking ring -B- must be located at the bottom of the circum‐
ferential groove -Arrow 2-.
Note


0FN”, page 249

es 0AV
♦ Mounting bracket - T10108/1-
♦ Three-arm extractor e. g. -VAS 251 205- or -Kukko 45-2-
♦ Thrust plate - MP3-467 (40-105)-
♦ Tapered-roller bearing extractor - V.A.G 1582-
♦ Gripper - V.A.G 1582/13-
♦ Press-on sleeve - MP3-412 (VW 455)-
♦ Thrust piece - MP3-411 (VW 454)-
♦ Mandrel - MP3-481/2 (VW 460/2)-
♦ Dial gauge
♦ Insert for key SW 36, head 3/4 "
♦ 2x screw M10 x 30
♦ 2x threaded bolt M8 x 30
♦ Screw M8 x 25 - 1 pc
♦ Nut M12 x 10 - 4 pcs
The inner ring/tapered-roller bearing is pressed onto the output
flange of the angle gearbox.

This will be removed later in the workflow.

Do not replace the tapered-roller bearing for the angle gearbox
output flange and the shims!
Removing
box mount.
– Lock output flange of angle gearbox with bracket - T10108/1-

that is attached with 2 screws M10 x 30 -arrows-.
– Loosen and remove nuts for output shaft flange.
A - Insert for key SW 36, head 3/4 "
– Pivot angle gearbox in assembly support so that the output
flange is facing up.
– Pull output flange off the shaft bevel gear of the angle gearbox.
A - Three-arm extractor e. g. -VAS 251 205- or -Kukko 45-2-

When removing the output flange, the inner ring / tapered roller
bearing and the sealing ring remain -arrow- on the output flange.
Removing gasket
• The inner ring / tapered-roller bearing must be pulled off the
output flange to remove the radial shaft seal ring.
– Place pressure plate - MP3-467 (40-105)- on the output
flange.
– Remove inner ring/taper roller bearing with tapered-roller

bearing extractor - V.A.G 1582- with gripper - V.A.G 1582/13-
from the output flange.
– Remove sealing ring from output flange.
Fitting sealing ring for output flange

• For the installation of the sealing ring, the drive pinion housing
-1- with shaft bevel gear -2- must first be removed.
– Unscrew fixing screws of drive pinion housing -1-.
– Carefully lift out the housing together with the drive pinion with
the shaft bevel gear -2- by crosswise levering of the proud
edges.
– Clean the thread on the shaft bevel gear.
• If the adjusting washer -3- was taken off when the output
flange was removed, this must be inserted again into the drive
pinion housing.
• The adjusting washer secures the preload of the shaft bevel
gear in the drive pinion housing.
– Put the inner ring / tapered-roller bearing -1- into the drive pin‐
ion housing.
– Lightly wet the new sealing ring -2- on the outer circumference
with gear oil.
• Fill half the space between the sealing lip and dust lip with
sealing grease - G 052 128 A1- .

– Push in new sealing ring with pressure piece - T10049- .

• Sealing ring must be flush with the upper edge of the housing.
– Gently press drive pinion housing with output flange onto the
shaft bevel gear up to the stop.
A - Press-on sleeve - MP3-412 (VW 455)-
B - Pressure spindle - MP3-408 (VW 412)-
C - Thrust piece - MP3-411 (VW 454)-
D - Pressure plate - MP3-406 (VW 401)-
• The shoulder -arrow- of the insertion bushing - MP3-412 (VW
455)- points to the shaft bevel gear.
• Rotate the drive pinion housing while pressing it on.
– Screw in threaded bolts M8 x 30 mm -A- into the angle gearbox

housing.
– Position the new O-ring -1- onto the drive pinion housing -2-.
• Lightly wet new O-ring with gear oil.
• Drive pinion housing and adjusting washer -3- only fit in one
position.
– Position adjusting washer -3-.
– Crosswise carefully press on fully the drive pinion housing
-2- with mandrel - MP3-481/2 (VW 460/2)- .
A small gap remains between the drive pinion housing and the
angle gearbox housing, which is closed by screwing in the drive
pinion housing.
– Stepwise crosswise tighten mounting screws for drive pinion
housing -2- to the desired tightening torque.
– Lightly wet the thread of the new nut for output flange with
locking agent - D 000 600- and tighten to the desired tightening
torque.
A - Insert for key SW 36, head 3/4 "
• After tightening the nut for the output flange, check the runout
on fixing bolt of the shaft bevel gear.

Measure the runout on the output flange of the shaft bevel gear
A - Universal dial gauge bracket - MP3-447 (VW 387)-
B - Screw M8 x 25
C - Dial gauge
– Fasten a universal dial gauge holder -A- with M8 x 25 bolt
-B- on the angle gearbox.
– Position the dial gauge -C- on the fixing bolt of the shaft bevel
gear -D-.
– Set the dial gauge to “0” with 1 mm bias.
– Rotate output flange one full turn -arrow-.
– Read measured value on the dial gauge.
• Runout: maximum 0.05 mm
Note


0AV”, page 251
4.3 Replacing gasket rings for angle gear‐

boxes
⇒ “4.3.1 Replacing sealing ring for angle gearboxes - on flange
shaft side”, page 266
⇒ “4.3.2 Replacing the sealing ring for the angle gearbox - Gear‐
box side”, page 267
4.3.1 Replacing sealing ring for angle gear‐

boxes - on flange shaft side
♦ Sealing grease - G 052 128 A1-
• The gearbox including angle gearbox is installed.
– Remove right flange shaft
⇒ “3.1.1 Removing and installing right flange shaft, vehicles
with four-wheel drive”, page 245 .
– Remove right sealing ring with extractor tool -T20143/2- .

– Half fill the space between sealing lip and dust lip -arrows- of
the new sealing ring with sealing grease -G 052 128 A1- .

stop.
– Mount the right flange shaft
– Checking the oil level
4.3.2 Replacing the sealing ring for the angle

gearbox - Gearbox side
♦ Sealing grease - G 052 128 A1-
– Pry out the sealing ring on the angle gearbox with extractor
tool - T20143/1- or -T20143/2- .

– Half fill the space between sealing lip and dust lip -arrows- of
the new sealing ring with sealing grease -G 052 128 A1- .

stop.
4.4 Replacing the right flange shaft needle

bearing
♦ Assembly tool - MP6-414/5 (3253/5)-
♦ Assembly tool - T10047-
♦
Work procedure
– Remove right flange shaft
– Position the
assembly device - T10047-
as shown.
• Marks “B” on both parts of the device point to each other
• The pegs -arrows - must be under the needle bearing.
– Screw on parts up to the stop.

– Remove detention ring -A- .

• In order to avoid damaging the contact surface of the needle
bearing on the shaft, turn the shaft while pressing -arrow-.
– Remove sealing ring -A- from groove -arrow-.

Installing
– Installation is carried out in the reverse order. When installing,
– Moisten sealing ring -A- with gear oil.

– Insert sealing ring -A- into the groove -arrow-.
– Install assembly device - T10047- ⇒ page 268 .
– Press in the new needle bearing.

• In order to avoid damaging the contact surface of the needle
bearing on the shaft, turn the shaft while pressing -arrow-.
– Secure the needle bearing with a new circlip.
– Mount the right flange shaft

7 Speed Dual Clutch Gearbox 0gc Eng

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Service

Service Department. Technical Information

4.2 Removing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

1.1 Safety precautions when working on ve‐

1.2 Safety precautions during road tests in

1.3 Safety measures during towing/tow-

1.4 General safety instructions

Risk of damage to the electronic components when disconnecting

2 Rep. gr.00 - Technical data

2.1 Gearbox identification

The gearbox identification characters are also printed on the

2.2 Marking angle gearbox

The identification is located in the lower part of the angle gearbox

4 Rep. gr.00 - Technical data

♦ The output flange of the “0CN” angle gear is fixed with a

3.1 Rules of cleanliness

3.2 General points

6 Rep. gr.00 - Technical data

Changes of gear-change point on upward and downward gradi‐

3.3 General repair instructions

The oil quality influences in a decisive way the function of the

8 Rep. gr.00 - Technical data

• If the overflow tube has to be replaced, you must install an

3.4 Seals and sealing rings

3.5 Screws, nuts

3.6 Contact corrosion

10 Rep. gr.00 - Technical data

4.1 Filling capacity

Check transmission oil level and top up with transmission oil if

Checking the oil level

4.2 Allocation gearbox - engine

4.2.1 Assignment gearbox - engine, Superb III

7-speed dual-clutch gearbox 0GC

Vehicles with petrol engines, four-wheel drive

Vehicles with diesel engines, front-wheel drive

Vehicles with diesel engines, four-wheel drive

4.2.2 Gearbox - engine assignment, Karoq

Volkswagen Technical Site: http://vwts.ru http://vwts.info

12 Rep. gr.00 - Technical data

Vehicles with diesel engines, four-wheel drive

4.2.3 Assignment gearbox - engine, Kodiaq

Vehicles with diesel engines, front-wheel drive

Vehicles with petrol engines, four-wheel drive

Vehicles with diesel engines, four-wheel drive

4.2.4 Gearbox assignment - Engine, Octavia II

14 Rep. gr.00 - Technical data

5.1 Fitting location summary - electrical components

1 - Mechatronics for double

1.1 Summary of components - Dual clutch

1 - Circlip of dual clutch end

1.2 Removing and installing the clutch end

16 Rep. gr.30 - Clutch

• The clutch cover and circlip must always be replaced after

18 Rep. gr.30 - Clutch

– Slide on the clutch cover in -direction of arrow A-, as shown in

It is possible to carefully lever the cover with a screwdriver -1- in