VW Golf7 7 Speed Dual Clutch Gearbox 0gc Eng

Service
Workshop Manual
Golf 2017 ➤ , Golf Sportsvan 2015 ➤ ,
Golf Sportsvan 2018 ➤ ,
Golf Variant 2017 ➤ , Tiguan 2016 ➤
7-speed dual clutch gearbox 0GC
Edition 07.2018
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.
Golf 2017 ➤ , Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ➤ , Golf Varia ...
7-speed dual clutch gearbox 0GC - Edition 07.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 General safety provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 2
1.3 Notes on tow-starting/towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Safety precautions when using testers and measuring instruments during a road test . . . . 2
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.5 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 Allocation gearbox - engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.1 Overview of fitting locations - electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1 Assembly overview - dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 Removing and installing clutch end cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3 Removing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4 Installing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1 Mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.1 Assembly overview - mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.2 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.3 Removing and installing mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2 Bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.1 Assembly overview - bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.2 Distinguishing between different types of bevel boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.3 Removing bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.4 Installing bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.1 Assembly overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.2 Emergency release from position P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.3 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.4 Moving push-button in the handle to installation position . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.5 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.6 Removing and installing gear selector cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.7 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.8 Checking and adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.9 Renewing selector shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.1 Specified torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.2 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.3 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
5 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Contents i
5.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

6 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
6.1 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
6.2 Transporting front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
7 Securing to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7.1 Installing gearbox to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7.2 Securing front differential lock to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . 158
8 Gear oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
8.1 Assembly overview - gear oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
8.2 Removing and installing gear oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
8.3 Removing and installing gear oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
8.4 Removing and installing motor for auxiliary hydraulic pump 1 for gearbox oil V475 . . . . . . 164
9 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
9.1 Overview of oil drain and inspection plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
9.2 Tools for gear oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
9.3 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
9.4 Draining and filling gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
10 Front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
10.1 Assembly overview - front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
10.2 Removing front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
10.3 Installing front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
10.4 Removing and installing differential lock control unit J647 . . . . . . . . . . . . . . . . . . . . . . . . 180
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

1 Currently, no repairs can be made to gears and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

1 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
1.1 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
1.2 Draining and filling gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
2 Oil for front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
2.1 Checking oil level for front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
2.2 Draining and filling oil for front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
3 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
3.1 Overview of fitting locations - seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
3.2 Renewing left seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
3.3 Renewing right oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
4 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
4.1 Removing and installing right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
5 Components of front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
5.1 Assembly overview - components of front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . 202
5.2 Checking function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
5.3 Removing and installing pump for front differential lock V181 . . . . . . . . . . . . . . . . . . . . . . 203
5.4 Removing and installing coupling for front differential lock . . . . . . . . . . . . . . . . . . . . . . . . 205
5.5 Renewing seals for front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
5.6 Renewing ball bearing for flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
6 Components of bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
6.1 Assembly overview - components of bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
6.2 Renewing bevel box seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
6.3 Renewing output flange and redetermining thickness of shim . . . . . . . . . . . . . . . . . . . . . . 241
ii Contents
00 – Technical data
1 Safety information
(VRL011928; Edition 07.2018)
⇒ “1.1 General safety provisions”, page 1
⇒ “1.2 Safety measures when working on vehicles with a start/
stop system”, page 2
⇒ “1.3 Notes on tow-starting/towing”, page 2
⇒ “1.4 Safety precautions when using testers and measuring in‐
struments during a road test”, page 2
1.1 General safety provisions

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

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

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

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

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

hicles with a start/stop system
Observe the following when working on vehicles with a start/stop
system:
WARNING
Risk of injury due to automatic start of engine on vehicles with

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

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

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

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

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

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

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

Disconnecting and reconnecting battery .
1. Safety information 3
2 Identification
2.1 Gearbox identification

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

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

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

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

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

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

which were otherwise repeated in the relevant sections of the
manual, are summarised here. They apply for this particular work‐
shop manual.
Guided Fault Finding, vehicle self-diagnosis and test instruments
♦ Before performing repairs to the gearbox, determine the cause
of the fault as accurately as possible ⇒ Vehicle diagnostic
tester, Guided Fault Finding , Vehicle Self-Diagnosis
or Test Instruments .
Special tool
For a complete list of special tools used in this workshop manual,
see ⇒ "Workshop equipment and special tools" .
Gearbox
Always make sure that no dirt can enter an »open« gearbox. In
particular, dirt entering an »exposed« mechatronic unit for dual
clutch gearbox - J743- and/or oil pump can lead to gearbox failure.
♦ If gearbox covers have been unbolted or gearbox has no fluid,
do not run engine or tow vehicle.
♦ First thoroughly clean connecting points and surrounding
areas and then loosen bolts.
♦ When installing the gearbox, ensure that dowel sleeves be‐
tween the engine and gearbox are correctly located.
Locking devices
♦ Do not overstretch retaining rings.
♦ Always renew retaining rings which have been damaged or
overstretched.
♦ Retaining rings must locate properly in grooves.
3.4 Gaskets and seals

♦ Renew O-rings, seals and gaskets.
♦ After removing gaskets and seals, always inspect contact sur‐
face of housing or shaft for burrs resulting from removal or for
other signs of damage.
♦ Before installing seals, lightly oil outer diameter and half-fill
space between sealing lips -arrow- with sealing grease -
G 052 128 A1- .
♦ The open side of the oil seals faces toward the side with fluid
filling.
♦ Only use dual clutch gearbox oil. Other lubricants will cause
problems in function.
♦ Coat O-rings with dual clutch gearbox oil to prevent pinching
of rings during assembly.
♦ After renewing gaskets, O-rings and seals, check oil level in
gearbox and top up if necessary ⇒ page 166 .

3.5 Nuts and bolts

♦ Loosen and tighten securing bolts and securing nut for covers
and housings diagonally.
♦ Specified torques given are for unlubricated nuts, bolts and
screws.
♦ Clean threads of bolts which are to be installed with locking
fluid using a wire brush. Then insert bolts with locking fluid -
AMV 185 101 A1- .
♦ Use a thread chaser to clear residual locking fluid from all
threaded holes into which self-locking bolts are to be screwed.
Otherwise there is a danger of bolts shearing when subse‐
quently being removed.
♦ Check pitch of thread, to ensure correct thread chaser is used
to clean threads and to ensure the threads are not damaged.
♦ Always renew self-locking bolts and nuts.
3. Repair instructions 7
4 Technical data
4.1 Allocation gearbox - engine
4.1.1 Golf SV 2015 ►

Take account of the gearbox code if spare parts are required for
a repair.
Dual clutch gearbox 0GC, front-wheel drive
Codes RAU, SKZ, SWU
Engine 2.0 l - 110 kW TDI
4.1.2 Golf 2017 ►

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

Codes SWR
4.1.3 Golf Estate 2017 ►

box code.
Codes RAU, SKZ, SWU RAU, SKZ, SWU
Engine 2.0 l - 110 kW TDI 2.0 l - 135 kW TDI

Codes RAV, SKY, SWR SWR
Engine 2.0 l - 135 kW TDI 2.0 l - 110 kW TDI
4.1.4 Golf SV 2018 ►

Take account of the gearbox code if spare parts are required for
a repair.
Dual clutch gearbox 0GC, front-wheel drive
Codes SWU, TNV, TDH
8 Rep. gr.00 - Technical data Volkswagen Technical Site: http://vwts.ru http://vwts.info

4.1.5 Tiguan 2016 ►

box code.
Codes SUL, UAY SWL, UBC
Engine 2.0 l - 110 kW TDI 1.5 I - 110 kW TSI

Codes SUK, UAJ TDE, UAM
Engine 2.0 l - 110 kW TDI 2.0 I - 140 kW TSI
4.2 Capacities
⇒ “4.2.1 Capacities - dual clutch gearbox”, page 9
⇒ “4.2.2 Capacities, front differential lock”, page 9
⇒ “4.2.3 Capacities, bevel box”, page 9
4.2.1 Capacities - dual clutch gearbox

Capacity Dual clutch gearbox 0GC
Initial filling 6.8 l ± 0.1 l
Changing approx. 6 l
♦ Change interval: ⇒ Maintenance manual and/
or ⇒ service tables “ELSA”
Lubricant Dual clutch gearbox oil
The oil is available as a replacement part; part no. ⇒ Electronic

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

Capacity of front dif‐
ferential lock
Capacity approx. 0.60 l
Change capacity ap‐ 0.40 l
prox.
• Change intervals:
⇒ Maintenance
tables

4.2.3 Capacities, bevel box

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

Further information in the part number designates the container
size.

5 Electrical components
5.1 Overview of fitting locations - electrical

components
⇒ “5.1.1 Overview of fitting locations - gearbox control”,
page 11
⇒ “5.1.2 Overview of fitting locations – electrical components,
front differential lock”, page 12
5.1.1 Overview of fitting locations - gearbox control
1 - Mechatronic unit for dual

clutch gearbox - J743-
❑ Removing and installing
⇒ page 31
2 - Gearbox input speed send‐
er - G182- and oil temperature
sender in multi-plate clutch -
G509-
❑ Not for this model
3 - Selector lever - E313-
❑ With selector lever sen‐
sors control unit - J587- ,
selector lever lock sole‐
noid - N110- and selec‐
tor lever locked in posi‐
tion P switch - F319-
❑ The components are in‐
tegrated into the printed
circuit of the selector
mechanism and cannot
be renewed separately
❑ Checking ⇒ vehicle di‐
agnostic tester
selector mechanism
⇒ page 58
5. Electrical components 11
5.1.2 Overview of fitting locations – electrical components, front differential lock
1 - Transverse lock-up control

unit - J647-
❑ Installed in lower area of
front differential lock.
❑ Transverse lock-up con‐
trol unit - J647- receives
important signals from
engine control unit and
control unit for ABS with
EDL - J104- via data
bus.
2 - Pump for front differential
lock - V181-
❑ Installed in lower area of
❑ Can be checked using
“guided fault finding” of
vehicle diagnosis, test‐
ing and information sys‐
tem - VAS 5051- .
3 - Diagnostic connection
❑ Location: in footwell,
front left
4 - Accelerator position sender
- G79- and accelerator position
sender 2 - G185-
⇒ Rep. gr. 20 ; Accel‐
erator mechanism; As‐
sembly overview - ac‐
celerator pedal module

30 – Clutch
1 Clutch
⇒ “1.1 Assembly overview - dual clutch”, page 13
⇒ “1.2 Removing and installing clutch end cover”, page 13
⇒ “1.3 Removing dual clutch”, page 17
⇒ “1.4 Installing dual clutch”, page 20
1.1 Assembly overview - dual clutch

Replacement parts
1 - Retaining ring for dual

clutch end cover
❑ Renew after removal
2 - Retaining ring for dual
clutch
3 - Retaining ring for drive plate
4 - Dual clutch
❑ Removing ⇒ page 17
❑ Installing ⇒ page 20
5 - Shims
❑ 10 spacer rings which
have different »thick‐
nesses«. They are sized
in 0.05 mm increments.
❑ Thickness of spacer ring
must be determined
when installing dual
clutch.
6 - Dual clutch end cover
⇒ page 13
1.2 Removing and installing clutch end cov‐

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

scratched sleeve.
Removing
• Cover and retaining ring must always be renewed.
– Drain gear oil ⇒ page 166 .
– Remove gearbox ⇒ page 71 .
– Secure gearbox in a vertical position on engine and gearbox
support ⇒ page 157 .
– Renew gear oil filter ⇒ page 163 .
– Lever out retaining ring -2- of clutch end cover using screw‐
driver -1- -arrow- and remove.
14 Rep. gr.30 - Clutch

– Lever off clutch end cover -2- through side opening in housing
using a screwdriver -1- or tyre lever -arrow- and remove clutch
end cover.
• The original clutch end cover and circlip must not be re-instal‐
led after removal.
Installing
Caution
Cover and retaining ring must always be renewed.

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

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

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

installing:
1. Clutch 15
– Clean assembly sleeve - T10459- “before using”. Do not use

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

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

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

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

– Do not remove bush until retaining ring is installed.

– Installing gearbox ⇒ page 150
– Top up gear oil ⇒ page 171 .
WARNING
Do not start engine if there is no oil in gearbox.
– After installation of gearbox, initiate default settings by

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

♦ 2 x hooks - 3438-
♦ Puller - T10055-
♦ Puller - T10525-
Brief description
• The axial play of the clutch is readjusted during installation
procedure.
1. Clutch 17
• To remove or install clutch, gearbox must be securely attached

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

-1- -arrow-.

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

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

to measure axial clearance.
– Remove shim -arrow-.
Caution
Carefully remove the dual clutch. Take care that no parts fall
out. Therefore, do not turn the clutch over!
– Engage 2 hooks - 3438- on opposite sides of clutch -arrow-.
1. Clutch 19
– Remove dual clutch using hooks - 3438- .
1.4 Installing dual clutch

♦ Universal dial gauge holder - VW 387-
♦ Dial gauge - VAS 6079-
♦ Retaining pins - T10524-

♦ Thrust piece - T10526-
Caution
♦ The drive plate has to remain engaged between the teeth

of the outer plate carrier.
♦ If the drive plate detaches, the plates in the dual clutch can
shift. It may then not be possible to adjust the clutch cor‐
rectly when it is installed.
♦ Do not lift (not even slightly) or remove plate carrier! The
plates could turn.
Brief description
• To remove or install the clutch, the gearbox must be securely
attached to an assembly stand in vertical position.
• The large plate carrier goes through all plates inside the clutch.
It must not slip out of the lowest plate.
Installing
– Take great care when removing the dual clutch from its pack‐
age.
– Turn piston rings by hand. They must move freely and must
not bind.
– Ensure that piston rings -1-, -2-, -3- and -4- are seated cor‐
rectly. The ring butts -arrows- of piston rings -1- and -3- should
align.
– The ring butts -arrows- of piston rings -2- and -4- should align
and be offset 180° to the ring butts of piston rings -1- and -3-.
1. Clutch 21
Important! Position of drive plate

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

• The retaining pin - T10524- should be held by a second me‐
chanic while the dual clutch is being inserted.
– Carefully insert -dual clutch-, ensuring it does not fall.

– If necessary, insert clutch by turning slightly.
The dual clutch is properly fitted if there is almost no play in the

retaining pin - T10524- .
Note
♦ The retaining pin remains inserted until the clutch end cover
is installed.
♦ The dual clutch must now not be rotated any more, as this can
shift the position of the retaining pin - T10524- .

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

-1- -arrow-.
Note
This retaining ring will be used again. Do not dispose of it.
– Apply puller - T10525- together with puller - T10055- on

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

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

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

• The retaining pin - T10524- remains installed!
– Temporarily install “old” retaining ring -arrow-.

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

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

save value “A” until the last measurement has been performed.
Second measurement

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

– Lift dual clutch with force to stop and note measurement.
– Call this value “B”.
Now calculate which shim must be fitted:
– Use this formula:
Value “B” minus value “A” minus 0.11 = thickness of shim to
be fitted.
– Note result.
The shims are sized in 0.05 mm increments.
– Measure the shims and determine which one is closest to the
result.
WARNING
Always use the next-largest shim, never the next-smallest.
Example:
Calculated dimension for shim New shim
1.28 mm 1.3 mm
1.26 mm 1.3 mm
– Remove old retaining ring -arrow-.
Note
Do not dispose of ring yet; it will be needed once more.
– Fit calculated shim.

Third measurement (check measurement)
To make sure that the shim is correct, a test measurement must
still be carried out. Proceed as follows:
1. Clutch 25
– Install old retaining ring -arrow- once more.
– Set tip of dial gauge -on hub of large plate carrier-.
Note
Set the tip of the dial gauge on the shim -1-.
– Set -dial gauge- to 0 with preload again.

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

– Fit drive plate into dual clutch.

• When installing, check if marking on drive plate is aligned with
marking on outer plate carrier -arrows-. If the markings were
subsequently make, align these.
– A second mechanic must hold retaining pin - T10524- in its
place and press outwards slightly.
– Carefully drive the drive plate onto its seat using press tool -
40-21- and a plastic hammer.
– Install drive plate retaining ring.
– Starting at the opening, press retaining ring in clockwise di‐
rection into its fitting position.
• The retaining ring must be fully engaged.
– Use screwdriver to check that retaining ring is correctly seated
and engaged.
– Now remove retaining pin - T10524- from between dual clutch
and housing.
– Install clutch end cover ⇒ page 13 .
1. Clutch 27
34 – Controls, housing
1 Mechatronic unit
⇒ “1.1 Assembly overview - mechatronic unit”, page 28
⇒ “1.2 Removing and installing sump”, page 29
⇒ “1.3 Removing and installing mechatronic unit”, page 31
1.1 Assembly overview - mechatronic unit
1 - Gearbox
2 - Mechatronic unit for dual
clutch gearbox - J743-
⇒ page 31
3 - Bolt
❑ Tightening sequence
⇒ page 29
4 - Seal
5 - Bolt
❑ 8 Nm + 60°
6 - Retaining clip
7 - Sump
⇒ page 29
Volkswagen Technical Site: http://vwts.ru http://vwts.info
28 Rep. gr.34 - Controls, housing

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

and tightening sequence
• Renew bolts after removing.
– Tighten bolts in 3 stages in the sequence shown:
Stage Bolts Specified torque/turning further angle
1. -1…9- Screw in to contact by hand
2. -1…9- 8 Nm
3. -1…9- Turn 45° further
1.2 Removing and installing sump

♦ Used oil collector and extractor - VAS 6622 A-
♦ Engine bung set - VAS 6122-
Removing
– Move selector lever to position “P”.
Always make sure that no dirt can enter an »open« gearbox.
1. Mechatronic unit 29
Caution
Risk of damage to gearbox.

♦ Do not run engine or tow vehicle with sump removed or
when there is no gear oil in the gearbox.
– Remove noise insulation ⇒ General body repairs, exterior;

Rep. gr. 66 ; Noise insulation; Removing and installing noise
insulation .
Vehicles with petrol engine
– Remove connecting hose between charge air cooler and
charge air pipe ⇒ Rep. gr. 21 ; Charge air system; Assembly
overview - charge air system .
Continued for all vehicles
– Remove electrical wiring and retainers from sump at front

-arrows-.
– Raise wiring in area of sump and secure it.
Caution
Risk of damaging mechatronic unit through electrostatic dis‐

charge.
♦ Do not touch contacts of mechatronic connector with the
hand.
– To become electrostatically discharged, touch an earthed ob‐

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

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

– Place used oil collection and extraction unit - VAS 6622- below
gearbox.
– Remove securing clip -3-.
– Unscrew bolts -1- diagonally and remove.
– Remove sump -2-. If necessary, lightly strike sump with a rub‐
ber-headed hammer to loosen.
Installing
Install in reverse order of removal, observing the following:
• Always renew the sump, the sump bolts and the retaining clip.
• Renew O-ring -arrow- on connector for mechatronic unit for
dual clutch gearbox - J743- .
Note
When renewing the mechatronic unit for dual clutch gearbox -

J743- , the O-ring will be supplied together with the new replace‐
ment part.
– Remove any oil and grease from sealing surface on gearbox

housing.
– Bring sump -2- into position and tighten new bolts -1- diago‐
nally in several stages.
• When positioning the sump, ensure that no cable connections
are trapped.
– Install new securing clip -3-.
• Offset side of retaining clip faces gearbox.
– Fit connector for mechatronic unit and engage.
– Top up gear oil and check gear oil level ⇒ page 166 .
Specified torques
♦ ⇒ “1.1 Assembly overview - mechatronic unit”, page 28
1.3 Removing and installing mechatronic

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

– Remove mechatronic unit -1- carefully.
Holding and carrying mechatronic unit

– Remove mechatronic unit for dual clutch gearbox - J743- .
Laying mechatronic unit to side properly

– Put down mechatronic unit so that sensors -arrows- are point‐
ing upwards.
Installing

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

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

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

– Top up gear oil and check gear oil level ⇒ page 166 .
– Adopt basic setting for mechatronic unit:
– Connect ⇒ Vehicle diagnostic tester and start Guided Func-
tions .
♦ 02 Gearbox electronics
♦ 02- Basic setting
Specified torques
♦ ⇒ “1.1 Assembly overview - mechatronic unit”, page 28
2 Bevel box
⇒ “2.1 Assembly overview - bevel box”, page 34
⇒ “2.2 Distinguishing between different types of bevel boxes”,
page 35
⇒ “2.3 Removing bevel box”, page 35
⇒ “2.4 Installing bevel box”, page 41
⇒ “6 Components of bevel box”, page 215
⇒ “6.2 Renewing bevel box seals”, page 219
2.1 Assembly overview - bevel box
1 - Bolt
❑ 25 Nm
2 - Heat shield
❑ For drive shaft.
❑ If present
3 - Nut
❑ Qty. 2 or 3
❑ If present
❑ Specified torque ⇒ Run‐
ning gear, axles, steer‐
ing; Rep. gr. 40 ; Sub‐
frame; Assembly over‐
view - subframe .
4 - Bolt
❑ 40 Nm
5 - Heat shield
❑ For propshaft.
6 - Bolt
❑ 20 Nm
7 - Bevel box
8 - Bolt
❑ Qty. 4
❑ Specified torque: 40 Nm
90°
9 - Bevel box carrier
❑ Different versions exist; for correct version refer to ⇒ Electronic parts catalogue (ETKA)
10 - Bolt
❑ Qty. 2
❑ Bevel box carrier to bevel box
❑ Specified torque and tightening sequence: ⇒ page 70
11 - Bolt
❑ Qty. 2

❑ Bevel box carrier to engine
❑ Specified torque and tightening sequence: ⇒ page 70
2.2 Distinguishing between different types

of bevel boxes
Installed is either bevel box “0AV / 0FV” or bevel box “0CN”
Bevel boxes can be identified by means of the following:
Area denoted by -arrow- is marked with “0AV” or “0CN”.
Additional distinguishing feature:
The output flange on the bevel box “0AV / 0FV” is secured with a
hexagon nut ⇒ Assembly overview - bevel box, “0AV / 0FV”
⇒ page 215 .
Output flange on bevel box “0CN” is secured with a twelve-point
nut ⇒ Assembly overview - bevel box, “0CN” ⇒ page 217 .
For more information, refer to ⇒ Rep. gr. 34 ; Bevel box .
2.3 Removing bevel box

♦ Socket insert - T10107 A-
♦ Counter-hold tool - T10172A-
2. Bevel box 35
♦ Engine support - T50015A-
♦ Bracket - T10533/2-
♦ Bolt - T10533/4-
♦ Hexagon key extension, 8 mm - 3247-
♦ Torque wrench - V.A.G 1331-
♦ Flange bolt M8 x 30 mm
♦ Grease for clutch plate splines ⇒ Electronic Parts Catalogue
(ETKA)

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

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

– Unscrew bolt -2- and push auxiliary pump for heating - V488-
to right side. Do not disconnect any lines ⇒ Rep. gr. 19 ;
Coolant pump, regulation of cooling system; Assembly over‐
view - electric coolant pump .
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .
– If fitted, remove drive shaft heat shield -1- from bevel box
-arrows- ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive
shaft .
Right drive shaft heat shield is secured with 2 or 3 nuts.
Caution
Risk of damage to flexible joint.

♦ Observe ⇒ Rep. gr. 26 ; Emission control; Assembly
overview - emission control .
2. Bevel box 37
– Remove clamp -2- from front exhaust pipe ⇒ Rep. gr. 26 ;

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

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

output shaft of bevel box -arrows-.
– Unbolt front propshaft from bevel box -arrows-.

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

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

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

– Place cloths on subframe to avoid damaging paint of propshaft
when it is placed on subframe.
– When pulling off or pushing on propshaft, always ensure that

sleeve -arrow- is not damaged.
– Push pendulum support to one side.
– Bolt bracket - T10533/2- -A- to engine support - T50015- -B-.

To do this, use an M8 x 30 bolt -1-.
– Bolt bracket -A- to gearbox using bolt - T10533/4- -C-.
– Bolt engine support -B- to subframe using an M8 bolt.
– Tighten bolts by hand.
– Push engine with engine support - T50015- as far forwards as
possible.
– Ensure that coolant hoses are not trapped between engine
and radiator.
– Pull propshaft off bevel box, and lay it on subframe.
2. Bevel box 39

– Unscrew bolts -1 and 2- and remove bevel box carrier.
Note
The next figure shows the bevel box with a splined shaft instead
of a flange shaft.
Vehicles with diesel engine

– Unscrew bolts -A and B-, and remove gearbox carrier -1- for
bevel box.
– Remove countersunk bolt for right flange shaft with socket -

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

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

Access to the upper bolts securing the bevel box to the gearbox
may be restricted depending on engine version.
Arrangement of upper bolts (-1- and -2-) for securing bevel box
to gearbox (hidden by bevel box).
♦ Bolt -1- is located in vicinity of bolt -A-
♦ Bolt -2- is located in vicinity of stud with hexagon drive -B-
♦ The front exhaust pipe with catalytic converter or particle filter
-C- is located above the bolts.
– Unscrew upper securing bolts -1- and -2- for securing bevel
box to gearbox.
– Unscrew lower bolts -arrows- securing bevel box to gearbox.

– Carefully press off bevel box and remove.
– Install bevel box ⇒ page 41 .
2.4 Installing bevel box
Note
♦ Refer to section “Removing bevel box” for required special

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

bolts -arrows- into bevel box at top.
– Push bevel box (with new securing bolts fitted at top) com‐
pletely onto gearbox, ensuring that splines of bevel box input
shaft and differential are centred when brought together.
– If splines are correctly positioned and shafts are centred, then
bevel box will slide to stop against gearbox.
Note
Do not use securing bolts to pull bevel box onto gearbox, or bevel
box will cant and bolt holes can break off.
Access to the upper bolts securing the bevel box to the gearbox
may be restricted depending on engine version.
Arrangement of upper bolts (-1- and -2-) for securing bevel box
to gearbox (hidden by bevel box).
♦ Bolt -1- is located in vicinity of bolt -A-
♦ Bolt -2- is located in vicinity of stud with hexagon drive -B-
♦ The front exhaust pipe with catalytic converter or particle filter
-C- is located above the bolts.
– Tighten upper and lower bolts -arrows- for securing bevel box
to gearbox. Specified torque: ⇒ page 70 .
– Bolt bevel box carrier to engine and bevel box, observing tight‐
ening sequence ⇒ page 70 .

Note
of a flange shaft.
Vehicles with diesel engine
– Secure flange shaft with new countersunk bolt. Specified tor‐

que: ⇒ Item 1 (page 34)
– Fit propshaft on bevel box.
Note
When removing and installing the bevel box, do not damage the
seal in the propshaft flange -arrow-. Renew propshaft if damaged.
2. Bevel box 43
– Bring bevel box and propshaft together by turning spindle of

engine support - T50015- -A-.
– When joining parts, ensure that markings -arrows- on flexible

coupling align with output flange of bevel box.
– Remove engine support - T50015A- .
– Bolt propshaft to bevel box -arrows- ⇒ Propshaft and rear final

drive; Rep. gr. 39 ; Propshaft; Removing and installing prop‐
shaft .
– Bolt on heat shield -1- . Specified torque: ⇒ page 34

– Secure pendulum support to gearbox using new bolts -1-.

Specified torque ⇒ Rep. gr. 10 ; Assembly mountings; As‐
sembly overview - assembly mountings
– Fit front exhaust system to engine ⇒ Rep. gr. 26 ; Exhaust
pipes/silencers; Assembly overview - silencer .
– Install right drive shaft ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Drive shaft; Removing and installing drive shaft .
– Mount drive shaft heat shield -1-, if present, on bevel box

(-arrows-) ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive
shaft .
Right drive shaft heat shield is secured with 2 or 3 nuts.
Continue installation in reverse order of removal.
– Check gear oil in bevel box ⇒ page 183 .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Assembly overview – noise insula‐
tion .
2. Bevel box 45
3 Selector mechanism
⇒ “3.1 Assembly overview - selector mechanism”, page 46
⇒ “3.2 Emergency release from position P”, page 47
⇒ “3.3 Removing and installing selector lever handle”,
page 49
⇒ “3.4 Moving push-button in the handle to installation position”,
page 57
⇒ “3.5 Removing and installing selector mechanism”, page 58
⇒ “3.6 Removing and installing gear selector cable”, page 62
⇒ “3.7 Checking selector mechanism”, page 64
⇒ “3.8 Checking and adjusting selector lever cable”, page 65
⇒ “3.9 Renewing selector shaft seal”, page 66
3.1 Assembly overview - selector mechanism
1 - Handle with selector cover

❑ Do not remove handle
without reason. For
emergency release, on‐
ly the cover needs to be
unclipped ⇒ page 47 .
⇒ page 49
2 - Bolt
❑ Qty. 4
❑ 8 Nm
3 - Selector mechanism
❑ With integrated selector
lever sensor control unit
- J587- with selector lev‐
er - E313- , Tiptronic
switch - F189- , switch
for selector lever locked
in P - F319- and selector
lever lock solenoid -
N110-
⇒ page 58
4 - Securing clip
❑ Always renew after re‐
moving.
5 - Nut
❑ Qty. 4
❑ For selector mechanism
to body
❑ 8 Nm
6 - Selector lever cable
❑ Selector lever cable is
not greased
❑ Removing and installing ⇒ page 62
❑ Checking and adjusting ⇒ page 65

7 - Bolt
❑ Adjuster screw for selector lever cable
❑ 13 Nm
8 - Cover
❑ Always renew after removing.
9 - Bolt
❑ Qty. 2
❑ 20 Nm
10 - Retaining clip
❑ Installation position: offset side of retaining clip faces gearbox selector lever
11 - Cable support bracket
❑ For selector lever cable
12 - Grommet
❑ Clip in on cable support bracket
❑ For cable support bracket mounting on gearbox
13 - Spacer
❑ Installation position: larger diameter faces gearbox
14 - Nut
15 - Bolt
❑ 10 Nm +90°
16 - Gearbox selector lever
3.2 Emergency release from position P

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

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

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

plying direct pressure to chrome frame, engage it in centre
console at front.
3.2.2 Emergency release from position P,

Golf SV 2015 ►, Golf SV 2018 ►
Do not remove knob.
– Using wedge - T10383- , carefully lever gear lever gaiter off
centre console insert -arrows-.

3.2.3 Emergency release from position P, Ti‐

guan 2016 ►
Do not remove knob.
– Fit wedge - T10383/2- at front between centre console and
selector cover, and lever selector cover off centre console by
carefully pushing wedge downwards.
3.3 Removing and installing selector lever

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

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

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

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

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

dle. Never install a handle with the button pressed in.
♦ Move push-button to installation position ⇒ page 57 .
♦ New handle is supplied with installation guard. Do not remove
guard until just before installing. To remove, pull out
-in direction of arrow-.
– Push handle fully onto selector lever and lock.

– Push sleeve downwards to lock.
Handle with clamp:

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

after being pressed. If this happens, remove handle again and
move push-button to installation position again ⇒ page 57 .
Then, fit the handle again.
Caution
The selector cover is surrounded by a chrome frame. Under

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

plying direct pressure to chrome frame, engage it in centre
console at front.

handle, Golf SV 2015 ►, Golf SV 2018 ►
♦ Hose clip pliers - V.A.G 1275 A-
♦ Wedges - T10383-
Brief description

Removing
– Using wedge - T10383- , carefully lever gear lever gaiter off
centre console insert -arrows-.
Pull off handle upwards without pressing push button -arrow-.

Note
Do not press button again after removal as it will otherwise no

longer be possible to install the handle.
Installing
Note

– Push handle fully onto selector lever and lock.

– Push sleeve downwards to lock.
Handle with clamp:

– Push on handle with new clamp -arrow- to stop.
– Secure clip with hose clip pliers - V.A.G 1275 A- .
Note

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

handle, Tiguan 2016 ►

♦ Hose clip pliers - V.A.G 1275-
♦ -T10383/2-
Brief description
Removing
– Shift selector lever to position “D”.
The push button -arrow- does not need to be pulled out by hand.
– Fit wedge - T10383/2- at front between centre console and

selector cover, and lever selector cover off centre console by
carefully pushing wedge downwards.

– Pull handle upwards off selector lever without pressing push
button.
Note
Do not press button again after removal as it will no longer be

possible to install the handle.
Installing
Note


– Push on handle with new clamp -arrow- to stop. Do not tighten

clamp yet.
Note

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

stallation position
If the button was pressed by mistake, the installation position can
be restored.
There are 2 ways of moving the push-button into the installation
position, »with« and »without« installation guard. Both of them are
described here.
Place handle »with« installation guard in installation position:
When using the installation guard, make sure that it has an eyelet
-arrow- at the front. Other types of installation guard are not suit‐
able.
– Holding down push button, completely push in installation

guard with eyelet -arrow- until installation guard engages, then
release push button. When the installation guard is pulled out,
the push-button engages in the installation position.
Place handle »without« installation guard in installation position:
– Carefully unclip handle trim -A- upwards.
– Using e.g. a screwdriver press small lever -1- for pull rod into
groove -2-. This action presses the push button -3- back into
installation position.
-I- = button pressed in
-II- = button in installation position
Note
♦ Only press the lever into the groove and no further.

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

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

anism with selector lever cable

♦ Release lever - 80-200-
Brief description
In the interior, the centre console must be removed.
The heat shield beneath the vehicle must be removed.
Removing
– Remove selector lever handle ⇒ page 49 .
– Remove centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; Centre console; Removing and installing centre con‐
sole .
– If fitted, remove footwell air duct ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air duct; Assembly overview - air routing and air
distribution in passenger compartment .
– Separate electrical connector from selector mechanism to ve‐
hicle wiring harness.
– Remove air filter housing ⇒ Rep. gr. 23 ; Air filter; Removing
and installing air filter housing
– Push ball socket -1- of selector lever cable off gearbox selector
lever using removal lever - 80-200- .
– Unscrew bolts -2- for cable support bracket.
– Do not bend or kink cable.
– Install centre tunnel heat shield below selector mechanism ⇒
General body repairs, exterior; Rep. gr. 66 ; Mouldings/trims/
extensions; Removing and installing floor heat shield .
– Remove bracket -A- if present.

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

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

repairs, exterior; Rep. gr. 66 ; Mouldings/trims/extensions;
Removing and installing floor heat shield .
– If featured, install footwell air duct ⇒ Heating, air conditioning;
– Install centre console ⇒ General body repairs, interior; Rep.
sole .
– Install selector lever handle ⇒ page 49 .
– Adjust selector lever cable ⇒ page 65 .
– Check selector mechanism ⇒ page 64 .
– Install air filter housing ⇒ Rep. gr. 23 ; Air filter; Removing
and installing air filter housing .
Specified torques
♦ Selector housing to body ⇒ page 46
3.5.2 Removing and installing selector mech‐

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


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

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

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

Always renew securing clip.
– Pull selector lever cable out of selector mechanism.
– Remove bracket -A- if present.

– Remove nuts -arrows- inside vehicle.
– Remove selector mechanism -B- together with selector hous‐
ing downwards.
Installing
doing this:
Note

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

“N”.
– Insert cable into selector mechanism, attach to selector lever
and fit new securing clip.
– If featured, install footwell air duct ⇒ Heating, air conditioning;
– Install centre console ⇒ General body repairs, interior; Rep.
sole .
– Install selector lever handle ⇒ page 49 .
Specified torques
♦ Selector housing to body ⇒ page 46
3.6 Removing and installing gear selector

cable

Removing
– Unscrew bolts -2- for cable support bracket.
– Shift selector lever on selector mechanism to position “N”. On‐
ly in this position the selector lever cable can be released.
– Using a screwdriver lever the cover off from under the selector
mechanism -arrow-.
Note
It is not permissible to reuse the cover. Always renew after re‐

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

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

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

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

“N”.
– Insert cable into selector mechanism, attach to selector lever
and fit new securing clip.
– Bring selector lever cable with cable support bracket into po‐
sition and tighten with bolts -2-.
– Do not press ball head -1- of selector lever cable onto gearbox
selector lever yet. Wait until selector lever cable has been
checked and adjusted.
– Check and adjust selector lever cable ⇒ page 65 .
Continue installation in reverse order of removal.
3.7 Checking selector mechanism

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

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

when the push-button is pressed. Solenoid for selector lever lock
blocks selector lever.
• Brake pedal is depressed:
Solenoid for selector lever lock releases selector lever. It is pos‐
sible to shift into a driving gear. Slowly shift selector lever from
“P” through to “S”, checking whether selector lever position in
dash panel insert corresponds to selector lever position.
Selector lever in “N” position and ignition switched on
• Brake pedal not depressed:
Selector lever is locked and cannot be shifted out of “N” position
with the push-button pressed. Solenoid for selector lever lock
blocks selector lever.
• Brake pedal is depressed:
Solenoid for selector lever lock releases selector lever. It is pos‐
sible to shift into a driving gear.
Selector lever in position “Tiptronic”
• Shift selector lever into Tiptronic gate.
The illumination of the “D” symbol in the selector mechanism cov‐
er must go out. “+” and “-” symbols must light up.
When the selector lever is shifted into the Tiptronic gate, the se‐
lector lever position display in the dash panel insert must change
from “P R N D S” to “6 5 4 3 2 1”.
Ignition and light switched on
The respective symbol in the shift mechanism cover lights up.
Selector lever position indicator
Simultaneous illumination of all selector lever position display
segments indicates gearbox emergency running mode.
3.8 Checking and adjusting selector lever

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

Always adjust selector lever cable if the following applies:
♦ The selector lever cable has been removed from the gearbox.
♦ The engine and/or gearbox has been removed and installed.
♦ Parts of the assembly mounting have been removed and in‐
stalled.
♦ The cable itself or the selector mechanism has been removed
and installed.
♦ The position of the engine and gearbox is shifted, for example
to install it free of tension.
Check
• Air filter housing is removed. ⇒ Rep. gr. 23 ; Air filter; Re‐
moving and installing air filter housing
– Switch selector lever to “P” position.
– Shift selector lever several times from position »P« to »S« and
back to »P«.
• Selector lever must move easily.
Adjusting
– Move selector lever in vehicle to “P” position.
– Selector shaft on gearbox is also in position “P”. To check,
push lever opposite to driving direction to rear stop.
Note
Raise vehicle, to be sure that the gearbox is in “P” (parking lock

engaged). It should not be possible to turn both front wheels to‐
gether in the same direction.
– Loosen adjustment screw -arrow- for selector lever cable.

– Gently push knob of selector lever forwards and backwards
but under no circumstances must you shift out of “P”.
– Tighten bolt -arrow- to 15 Nm.
This completes the adjustment.
– Install air filter housing.
– ⇒ Rep. gr. 23 ; Air filter; Removing and installing air filter
housing
3.9 Renewing selector shaft seal

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

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

Sequence of operations
• Gearbox is installed.
• Renew bolts that are tightened with turning further angle after
each removal.
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery .
– Unscrew bolt -arrow- and remove gearbox selector lever -1-.
– Lever out seal using extractor hook - T20143/1- -arrow-.
– Apply gear oil to circumference and sealing lips of new oil seal.
– Fill half of the space between sealing lip and dust lip -arrow-
with sealing grease ⇒ Electronic parts catalogue .

– Drive in seal to stop with tube - VW423- , being careful not to

cant seal.
• Closed side of oil seal -arrow- faces towards outside.
– Place gearbox selector lever -1- on shaft for parking lock and
tighten bolt -arrow-.
– Push selector lever onto gearbox selector lever, and adjust
selector lever cable ⇒ page 65 .
– Install battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery tray .
Specified torques
♦ ⇒ “3.1 Assembly overview - selector mechanism”, page 46
4 Removing and installing gearbox

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

Item Bolt Nm
1, 2, 3 M12x55 80
• With insert tool
T10179 or
T10509:
»65 Nm«
4 M12x65 80
5, 6, 7 M10x50 40
8, 9 M12×70 80
A Dowel sleeves for centring
Component Nm
Assembly mountings to gearbox (renew bolts after 60 Nm + turn 90° further
each removal)
Earth strap to assembly mounting 25
Heat shield for right drive shaft to bevel box 20
Propshaft to bevel box ⇒ Rep. gr. 39 ; Propshaft; Assembly overview - prop‐
shaft
Bevel box to gearbox

Bevel box to gearbox ⇒ “2.1 Assembly overview - bevel
♦ Renew bolts after re‐ box”, page 34
moving.
4.1.1 Gearbox carrier to engine and bevel box

Installation location and tightening sequence:
Petrol engine
Item Bolt
1 M10 x 45
2 M10 x 21
Sequence Bolts Specified torque

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

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

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

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

⇒ “4.2.1 Removing gearbox, Golf SV 2015 ►, Golf SV 2018 ►,
vehicles with diesel engine, front-wheel drive”, page 71
⇒ “4.2.2 Removing gearbox, Golf 2017 ►, Golf Estate 2017 ►,
vehicles with diesel engine, front-wheel drive”, page 83
⇒ “4.2.3 Removing gearbox, Golf 2017 ►, Golf Estate 2017 ►,
vehicles with diesel engine, all-wheel drive”, page 97
⇒ “4.2.4 Removing gearbox, Golf 2017 ►, vehicles with petrol en‐
gine”, page 108
⇒ “4.2.5 Removing gearbox, Tiguan 2016 ►, vehicles with diesel
engine, all-wheel drive”, page 118
⇒ “4.2.6 Removing gearbox, Tiguan 2016 ►, vehicles with diesel
engine, front-wheel drive”, page 128
⇒ “4.2.7 Removing gearbox, Tiguan 2016 ►, vehicles with 1.5 l
petrol engine, front-wheel drive”, page 135
⇒ “4.2.8 Removing gearbox, Tiguan 2016 ►, vehicles with 2.0 l
petrol engine, all-wheel drive”, page 141
4.2.1 Removing gearbox, Golf SV 2015 ►,

Golf SV 2018 ►, vehicles with diesel en‐
gine, front-wheel drive
Brief description
The gearbox is removed downwards separately. The engine re‐
mains in the vehicle.
Battery, battery carrier and air cleaner housing are removed
»from above«. Engine and gearbox must then be supported so
that left assembly mounting can be detached.
»From below«
4. Removing and installing gearbox 71

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

equipment required
♦ Support - 10 - 222 A-
♦ Adapter - 10 - 222 A /29-
♦ Adapter - 10 - 222 A /18-
♦ Shackle - 10 - 222 A /12-
♦ Pin - 3282/29-
♦ Gearbox support - 3282-

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

♦ Release lever - 80 - 200-
♦ Insert tool, 18 mm - T10179-
♦ Multi-point bit - T10061-

♦ Adapter - 10 - 222 A /3-
♦ Bracket - T10346/1-
Removing
height.
– Switch selector lever to »P« position.
Note

– Depress brake pedal to remove bolt for left drive shaft

-arrow- (second mechanic required).
– Remove engine cover panel ⇒ Rep. gr. 10 ; Engine cover
panel; Removing and installing engine cover panel .
– Pull off bleeder connection -1-, if fitted, with breather hose from
locking mechanism -arrow- of battery tray -3-.
– Remove battery with battery tray ⇒ Electrical system; Rep.
gr. 27 ; Battery; Removing and installing battery tray .
– Remove bolts -arrows-

– Open screw-type clip -3- and remove charge air pipe -1- ⇒
Rep. gr. 21 ; Charge air system; Assembly overview - charge
air system .
Disregard screw-type clip -2-.
– Lever off selector lever cable -1- from gearbox selector lever
using removal lever - 80 - 200- .
– Unscrew bolts -2-, raise and tie cable support bracket -3- to‐
gether with selector lever cable.

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

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

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

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

by turning in direction of starter and pull off connector.
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
Removing and installing starter .
– Remove charge air line. ⇒ Rep. gr. 21 ; Charge air system;
Assembly overview - charge air system
– Unscrew upper engine/gearbox connecting bolts using insert

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

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

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

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

which faces towards wing -arrows-.
The adapter on the “right” side of the vehicle is engaged in the
recess of the wing.

– Push adapter - 10 - 222 A /18- and adapter - 10 - 222 A /3-

onto support bracket - 10-222 A- .
– Secure support bracket - 10-222 A- to adapters - 10 - 222 A /
29- .
• Secure both adapters - 10 - 222 A /29- with tensioning straps

- T10038- .
• The tensioning strap - T10038- must be attached in recess
-arrow- in bonnet hinge.
– Then, attach spindles in engine lifting eyes.
– Take up weight of engine/gearbox assembly and support
bracket on spindles .
insulation .
– Remove lower part of front left wheel housing liner ⇒ General
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; As‐
sembly overview - front wheel housing liner .
Vehicles with window washer system:
– Detach nut -3- from washer fluid reservoir -4- ⇒ Electrical

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


-arrows-.
– Release electrical connector for auxiliary hydraulic pump 1 for

gearbox oil - V475- -a- and pull off connector -b-.
– Detach connector -1- from oil level and oil temperature sender
- G266- , if fitted.
– Remove left drive shaft ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Drive shaft; Removing and installing drive shafts .
– If fitted, remove heat shield for right drive shaft -arrows- ⇒

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

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

pension strut.
The surface protection of the shafts must not be damaged.
– Remove clamp -2- for exhaust system from engine then raise
and tie front exhaust pipe ⇒ Rep. gr. 26 ; Exhaust pipes/
silencers; Assembly overview - silencer .
– Remove pendulum support. First remove bolt -1-, followed by

bolts -2- and -3-.
– Remove all but one »easily accessible« connecting bolt be‐
tween engine and gearbox from underneath.
– Remove bolts -arrows- of assembly mounting for gearbox.

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

engine/gearbox »only« on gearbox side as far as dimension
-a-.
Dimension -a- = about 80mm
– Remove radiator cowl with radiator fan -arrow- ⇒ Rep. gr. 19 ;

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

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

Gearbox support - 3282- is aligned with adjustment plate -

3282/61- for removal of gearbox 0GC.
– Gearbox support - 3282- is inserted in engine and gearbox
jack - VAS 6931- .
– Align arms of gearbox support according to holes in adjust‐
ment plate .
– Screw support elements -A- into adjustment plate as illustra‐
ted. Deviating from this, pin - 3282/34- is used as rear right
support element. This support element is located outside ad‐
justment plate .
• Support element -C- on adjustment plate is not used.
– Position engine and gearbox jack - V.A.G 1383 A- with gear‐
box support - 3282- under gearbox.
All gearboxes are supported as shown in the illustration.
– Mount safety support -1- and hook -2- on gearbox as shown.
– Mount safety support -3- and pin -4- on gearbox as shown.

– Remove »last« connecting bolt between engine and gearbox.
– Push gearbox off engine and lower it carefully, ensuring
»clearance« to other components.
Note
Be careful of all lines when lowering gearbox.
Transporting gearbox ⇒ page 155 .

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

Estate 2017 ►, vehicles with diesel en‐
gine, front-wheel drive
Brief description
that left assembly mounting can be detached.
»From below«

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

equipment required
♦ Support - 10 - 222 A-
♦ Adapter - 10 - 222 A /29-
♦ Not required: adapter - 10 - 222 A /18-
♦ Shackle - 10 - 222 A /12-
♦ Pin - 3282/29-

♦ Engine and gearbox

jack - VAS 6931-
♦ Adjustment plate -
3282/61-
♦ Hose clamps to 25
mm - 3094-
♦ Tensioning strap -
T10038-

♦ Engine bung set -

VAS 6122-
♦ Insert tool, 18 mm -
T10179-
♦ Multi-point bit -
T10061-
♦ Adapter - 10 - 222 A /
3-

♦ Release lever - 80 -
200-
♦ Engine support -
T50015A-
♦ Bracket - T10346/1-
♦ Square tube -
T40091/1- , qty. 2
♦ Connecting piece -
T40091/3- , qty. 2

♦ Spindle - T40093 /3-

from engine support
supplementary set -
T40093- , qty. 2
♦ Adapter -
T40093/3-6- : qty. 2
(check and modify as
necessary
⇒ page 88 )
♦ or adapter -
T40093/3-6A- : qty. 2
Check adapters -
T40093/3-6- and modify
as necessary
– If necessary, cut off
the marked area.
– Round off front
edges.
– Protect adapter
against corrosion.
– Then, mark adapters
- T40093/3-6- as -
T40093/3-6A- .
At a later point, support
bracket - 10-222 A- will
be fitted onto longitudinal
members with adapters -
T40093/3-6A- .
• To prevent damage
to the longitudinal
members, wrap the
front section of the
adapters -
T40093/3-6A- with
textile-reinforced ad‐
hesive tape ⇒ Elec‐
tronic parts catalogue
(ETKA chemical sub‐
stances) .

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

bolt, do not lower vehicle
to ground again.
– Depress brake pedal to remove bolt for left drive shaft

-arrow- (second mechanic required).


air system .
Note

open carefully.

escaping coolant.




– Remove fuel filter and lay to side. Do not open pipe/hose sys‐
tem ⇒ Rep. gr. 20 ; Fuel filter; Assembly overview - fuel filter .
now.
Required material:
♦ Adapter - 10 - 222 A /3-
♦ Adapter - 10 - 222 A /29- , qty. 2
♦ Square tube - T40091/1-
♦ Connector - T40091/3-
♦ Spindle - T40093 /3-
♦ Check adapter - T40093/3-6- and modify as necessary
⇒ page 88
♦ or adapter - T40093/3-6A-


wing underneath it.

vehicle.

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

bracket - 10-222 A- .
29- .
-A- = adapter - T40093/3-6A- (⇒ next figure)

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

tudinal members -arrow-. Do not disconnect pipe/hose sys‐
tem.
– Place adapter - T40093/3-6A- onto right longitudinal member.
– If necessary, carefully unclip any pipes for air conditioning
system in front area. Do not disconnect pipe/hose system ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - refrigerant circuit .
– Bolt on spindle - T40093 /3- .
– Connect spindle - T40093 /3- via square tube - T40091/1- to
engine support bracket - 10-222 A- and fasten the connection
(⇒ previous fig.).
– Then attach spindles to engine support eyes.
insulation .
– Detach nut -3- from washer fluid reservoir -4- ⇒ Electrical

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

-arrows-.


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

moving and installing drive shaft heat shield .
– Remove right drive shaft from gearbox. ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Drive shaft; Removing and in‐
stalling drive shaft .
– Use tensioning strap - T10038- to secure drive shafts on sus‐

pension strut.

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

bolts -2- and -3-.
tween engine and gearbox from underneath.

-a-.
Volkswagen Technical Site: http://vwts.ru http://vwts.info 4. Removing and installing gearbox 95

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

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

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

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

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

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

4.2.3 Removing gearbox, Golf 2017 ►, Golf

Estate 2017 ►, vehicles with diesel en‐
gine, all-wheel drive
Brief description
The gearbox is removed downwards together with the bevel box.
»From above«
The battery, air filter and starter are removed. The coolant hoses
must be clamped off. Support engine and gearbox before left
subframe mounting is unbolted.
»From below«
The -subframe- is removed together with -pendulum support- and
-both suspension links-.
Both drive shafts are disconnected from gearbox and left installed
in wheel bearing housings. They are only swivelled to one side
and left on vehicle.


equipment required
♦ Support - 10-222A-
♦ Shackle - 10 - 222 A /12-
♦ Support - 10 - 222 A /31-
♦ Engine support, basic set - T40091-
♦ Engine support supplement set - T40093-


♦ Insert tool 18 mm - T10179- or insert tool AF 18 - T10509-
♦ Socket insert - T10061-
♦ Support bridge - T10323-

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


air system .

Note

open carefully.

escaping coolant.

– Seal connecting necks of gear oil cooler using suitable plugs
from engine bung set - VAS 6122- .

It is advisable to remove the »lower« bolt first.


– Remove fuel filter and lay to side. Do not open pipe/hose sys‐
tem ⇒ Rep. gr. 20 ; Fuel filter; Assembly overview - fuel filter .
now.
Required material:
♦ Adapter - 10 - 222 A /3-
♦ Adapter - 10 - 222 A /29- , qty. 2
♦ Square tube - T40091/1-
♦ Connector - T40091/3-
♦ Spindle - T40093 /3-
♦ Check adapter - T40093/3-6- and modify as necessary
⇒ page 88
♦ or adapter - T40093/3-6A-

wing underneath it.

vehicle.


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

bracket - 10-222 A- .
29- .

tem.
– Place adapter - T40093/3-6A- onto right longitudinal member.
– Bolt on spindle - T40093 /3- .
– Connect spindle - T40093 /3- via square tube - T40091/1- to
engine support bracket - 10-222 A- and fasten the connection
(⇒ previous fig.).
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; Re‐
moving and installing front wheel housing liner .

– Remove electrical wiring and retainer from front of sump

-arrows- (2 x M6 nuts).
– If fitted, pull connector -1- off oil level and oil temperature
sender - G266- .
– If fitted, pull connector off auxiliary pump for heating - V488-
⇒ Rep. gr. 19 ; Coolant pump, thermostat; Assembly overview
- electric coolant pump .
– Remove subframe ⇒ Running gear, axles, steering; Rep. gr.
40 ; Subframe; Removing and installing subframe without
steering rack .
– Remove drive shaft heat shield, if present, from bevel box ⇒

Running gear, axles, steering; Rep. gr. 40 ; Drive shafts; Re‐
moving and installing drive shafts .
Right drive shaft heat shield is secured with 2 or 3 nuts -arrows-.
– Detach left and right drive shafts from gearbox ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and
installing drive shaft .
– Secure both drive shafts on suspension strut with tensioning

belts - T10038- .

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

-1-.

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

Propshaft; Removing and installing propshaft .


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

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

propshaft flange -arrow-.
♦ Renew propshaft if damaged. ⇒ Rep. gr. 39 ; Propshaft; Re‐
moving and installing propshaft
♦ All parts of propshaft which have been marked relative to each
other must be reinstalled in the same positions.


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

bevel box -A-.

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

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


equipment required
♦ Support - 10 - 222 A-
♦ Adapter - 10 - 222 A /29-
♦ Adapter - 10 - 222 A /18-
♦ Shackle - 10 - 222 A /12- qty. 2
♦ Pin - 3282/29-

♦ Adjustment plate - 3282/42 A-

♦ Insert tool, 18 mm - T10179-

♦ Release lever - 80 -
200-
♦ Insert tool 18 mm -
T10179- or insert tool
AF 18 - T10509-
♦ Socket insert -
T10061-
♦ Square tube -
T40091/1- , qty. 2
♦ Connecting piece -
T40091/3- , qty. 2

♦ Spindle - T40093 /3-

from engine support
supplementary set -
T40093- , qty. 2
♦ Adapter -
T40093/3-6- : qty. 2
(check and modify as
necessary
⇒ page 112 )
♦ or adapter -
T40093/3-6A- : qty. 2
♦ Adjustment plate -
3282/61-
Check adapters -
T40093/3-6- and modify
as necessary
– If necessary, cut off
the marked area.
– Round off front
edges.
– Protect adapter
against corrosion.
– Then, mark adapters
- T40093/3-6- as -
T40093/3-6A- .
At a later point, support
bracket - 10-222 A- will
be fitted onto longitudinal
members with adapters -
T40093/3-6A- .

• To prevent damage
to the longitudinal
members, wrap the
front section of the
adapters -
T40093/3-6A- with
textile-reinforced ad‐
hesive tape ⇒ Elec‐
tronic parts catalogue
(ETKA chemical sub‐
stances) .
Removing
– Raise vehicle. All 4
supports of lifting
platform must be at
same height.
– Move selector lever
to position »P«.
– Remove engine cov‐
er panel ⇒ Rep. gr.
10 ; Engine cover
panel; Removing and
installing engine cov‐
er panel .
– Remove air filter
housing ⇒ Rep. gr.
24 ; Air filter; Remov‐
ing and installing air
filter housing
– Remove battery and
battery tray ⇒ Electri‐
cal system; Rep. gr.
27 ; Battery; Remov‐
ing and installing bat‐
tery
– Remove charge air pipe with charge air hose ⇒ Rep. gr. 21 ;
Charge air system; Assembly overview - charge air system .
escaping coolant.
Note

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



– Remove all upper engine/gearbox connecting bolts.

support eye for support bracket - 10-222A- , remove these
now.
Required material:
♦ Adapter - 10 - 222 A /18-
♦ Shackle - 10 - 222 A /12- : qty 2 (required if spindles of support
bracket cannot be hooked into lifting eyes of engine).
♦ Adapter - 10 - 222 A /29- , qty. 2
♦ Square section tube - T40091/1- , qty. 2
♦ Connecting piece - T40091/3- , qty. 2
♦ Spindles - T40093 /3- qty. 2
♦ Adapter - T40093/3-6- : qty. 2 (check and modify as necessary
⇒ page 88 )
♦ or adapter - T40093/3-6A- : qty. 2

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

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

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


tem.
– Place adapters - T40093/3-6A- onto both longitudinal mem‐
bers (illustration shows right longitudinal member).
– Position adapter - T40093/3-6A- on left longitudinal member

directly behind filler pipe for washer fluid reservoir.
• Each of the adapters - T40093/3-6A- locks with pin -A- behind
the web of the longitudinal member -arrow-.
– Screw in spindles - T40093 /3- .
– Connect spindles - T40093 /3- via square tubes - T40091/1-
to engine support bracket - 10-222 A- , and tighten (⇒ previous
illustration).
sulation .


Vehicles with front differential lock

– Pull connector -arrow- off transverse lock-up control unit -
J647- .
Continuation for all
steering rack .

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

T10038- .


-a-.
Vehicles with front differential lock

– One engine/gearbox connecting bolt -arrow- is located next to

ble«. Slightly tilt gearbox on the outside using spindle of gear‐
box support - 3282- .
– Now slightly turn gearbox and lower it. Be sure to guide flange
-1- past intermediate plate -arrow- when lowering gearbox.
Note

4.2.5 Removing gearbox, Tiguan 2016 ►, ve‐

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

The battery is disconnected and, if located in engine compart‐

ment, removed. The air filter and starter are removed. The engine
and gearbox must be supported before the left subframe mount‐
ing is removed.
»From below«
-Subframe- is removed together with -pendulum support- and



♦ Pin - 3282/29-
Removing
height.
– Move selector lever to position »P«.
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery
– Remove air intake pipe ⇒ Rep. gr. 21 ; Charge air system;
Removing and installing air intake pipe .

Note

open carefully.

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

3094- and remove.
– Disconnect connector -1- for mechatronic unit for dual clutch

gearbox - J743- . To do this, turn rotary locking mechanism
anti-clockwise -arrow-.
– Remove starter -A- ⇒ Electrical system; Rep. gr. 27 ; Starter;
It is advisable to remove the lower bolt first.


– Support engine and gearbox in installation position ⇒ Rep. gr.
10 ; Assembly mountings; Supporting engine in installation
position .
Rep. gr. 66 ; Noise insulation .

– Remove subframe ⇒ Rep. gr. 40 ; Subframe; Assembly over‐
view - subframe .

– If fitted, remove drive shaft heat shield -1- from bevel box ⇒
moving and installing drive shaft .
Heat shield is secured with 2 or 3 nuts -arrows-.
shaft .


T10038- .
Note
of a flange shaft.
– Unscrew bolts -A- and -B-, and remove bevel box carrier -1-.
– Unscrew bolts -A- and -B- from bevel box and remove heat
shield -1-.





hole for subframe.
Note


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

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

gearbox.

-a-.

bevel box -A-.


– Make sure to guide bevel box past intermediate plate when
lowering gearbox.
Note


hicles with diesel engine, front-wheel
drive
Brief description
that left and right assembly mounting can be detached.
»From below«
Remove noise insulation beneath engine and cover in front left
wheel housing.
-steering rack-.
Both drive shafts are pushed out of gearbox and left installed in
wheel bearing housings. They are only swivelled to one side, but
are left on vehicle.
♦ Pin - 3282/29-



♦ Pin - 3282/29-
Removing
height.
– Switch selector lever to »P« position.
– Remove air intake pipe ⇒ Rep. gr. 21 ; Charge air system;
Removing and installing air intake pipe .

Note

open carefully.

escaping coolant.




position .
insulation .

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

axles, steering; Rep. gr. 40 ; Drive shaft: Removing and in‐
stalling drive shafts .
Secure both drive shafts to suspension struts using tensioning

straps - T10038- .
tween engine and gearbox.

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

gine ⇒ Rep. gr. 10 ; Assembly mountings; Assembly overview
- assembly mountings .

gearbox.

-a-.

– Press gearbox off engine, and (if not already done) remove
gearbox carrier while »observing selector lever cable«, and
lower gearbox.


hicles with 1.5 l petrol engine, front-
wheel drive
Brief description
»From above«
The battery, air filter and starter are removed. The engine and
gearbox must be supported before the left subframe mounting is
removed.
»From below«


♦ Pin - 3282/29-
Removing
height.

27 ; Battery; Removing and installing battery tray .
Note

open carefully.

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

3094- and remove.

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

gearbox - J743- . To do this, turn rotary locking mechanism
anti-clockwise -arrow-.
It is advisable to remove the lower bolt first.

position .
Rep. gr. 66 ; Noise insulation .

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


shaft .

T10038- .

gearbox.

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


lowering gearbox.
Note


hicles with 2.0 l petrol engine, all-wheel
drive
Brief description
»From above«
The battery is disconnected and, if located in engine compart‐
ment, removed. The air filter and starter are removed. The engine
and gearbox must be supported before the left subframe mount‐
ing is removed.
»From below«



♦ Pin - 3282/29-
Removing
height.
27 ; Battery; Removing and installing battery

– Remove charge air pipe with charge air hose ⇒ Rep. gr. 21 ;
Charge air system; Assembly overview - charge air system .
escaping coolant.
Note

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


– Remove all upper engine/gearbox connecting bolts.

position .
sulation .

steering rack .

– If fitted, remove drive shaft heat shield -1- from bevel box ⇒
moving and installing drive shaft .
Heat shield is secured with 2 or 3 nuts -arrows-.
shaft .


T10038- .
– Unscrew bolts -1- and -2-, and remove gearbox carrier from
bevel box.
– Unscrew bolts -A- and -B- from bevel box and remove heat
shield -1-.





hole for subframe.
Note



-a-.

bevel box -A-.


ble«. Slightly tilt gearbox on the outside using spindle of gear‐
box support - 3282- .
lowering gearbox.
Note

4.3 Installing gearbox

Install in the reverse order of removal, observing the following.
– Renew needle bearing in crankshaft ⇒ Rep. gr. 13 ; Crank‐
shaft; Renewing needle bearing in crankshaft .
Note
If the needle bearing in the crankshaft is damaged, the gears

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

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

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

-arrow- ⇒ Rep. gr. 19 ; Radiator, radiator fan; Removing and
installing radiator cowl .
– Reinstall nut -3- on washer fluid reservoir -4-. Specified torque:

⇒ Electrical system; Rep. gr. 92 ; Windscreen washer system;
Removing and installing washer fluid reservoir .
– Install pendulum support with new bolts. Specified torque: ⇒

Rep. gr. 10 ; Assembly mountings; Assembly overview - as‐
sembly mountings .
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Re‐
moving and installing starter .
– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shaft; Removing and installing drive shaft .

– If fitted, install heat shield for right drive shaft -arrows- ⇒ Run‐
ning gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing
and installing drive shaft heat shield .
– Carefully remove strainer -1- of oil cooler with a screwdriver

and check for contamination.
– Clean strainer if necessary and clip back in place
– Fit coolant hoses on gear oil cooler.
– Install wire retainer on sump.
– Fit all electrical connectors on gearbox.
– Install battery tray and battery ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery .
– Check coolant level ⇒ Rep. gr. 19 ; Cooling system, coolant;
Draining and filling coolant .
– Install lower part of front left wheel housing liner ⇒ General
gr. 66 ; Noise insulation; Removing and installing noise insu‐
lation .
Specified torques: ⇒ page 70

5 Assembly mountings
⇒ “5.1 Assembly overview - assembly mountings”, page 153
5.1 Assembly overview - assembly mountings
1 - Engine support
❑ ⇒ Rep. gr. 10 ; Assem‐
bly mountings; Assem‐
bly overview - assembly
mountings
2 - Engine mounting
❑ ⇒ Rep. gr. 10 ; Assem‐
bly mountings; Assem‐
bly overview - assembly
mountings
3, 4, 5 - Bolt
❑ Specified torque ⇒ Rep.
gr. 10 ; Assembly
mountings; Assembly
overview - assembly
mountings
6 - Bracket
❑ Version
7, 8, 9 - Bolt
gr. 10 ; Assembly
mountings; Assembly
overview - assembly
mountings
10 - Pendulum support
11 - Bolt
❑ For pendulum support
to subframe
gr. 10 ; Assembly
mountings; Assembly
overview - assembly
5. Assembly mountings 153

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

dulum support.
Note
♦ There are threaded inserts, e.g. “Heli-Coil” in the bolting holes

for the pendulum support.
♦ Distinguishing feature: shoulder along beginning of thread
-arrow-.
♦ Note appropriate securing bolts and specified torque ⇒ Rep.
gr. 10 ; Assembly mountings; Assembly overview - assembly
mountings .

6 Transporting gearbox
⇒ “6.1 Transporting gearbox”, page 155
⇒ “6.2 Transporting front differential lock”, page 156
6.1 Transporting gearbox

♦ Gearbox mounting support - 3336-
♦ Workshop hoist - VAS 6100-
Transporting gearbox
– Bolt gearbox lifting tackle - 3336- to gearbox. When doing this,
lock in housing recess -arrow-.
6. Transporting gearbox 155

– Adjust support beam on sliding piece using locking pin

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

• Protect connectors on front differential lock from being dam‐
aged.
– Prepare front differential lock for transport as follows so that
no oil can escape:
• Pump for front differential lock - V181- -arrows- is in one of
illustrated positions during transport.

7 Securing to engine and gearbox sup‐

port
⇒ “7.1 Installing gearbox to engine and gearbox support”,
page 157
⇒ “7.2 Securing front differential lock to engine and gearbox sup‐
port”, page 158
7.1 Installing gearbox to engine and gear‐

box support
♦ Support plate - VW 309-
♦ or support plate - VW 309 A-
♦ Gearbox support - VW 353-
♦ Engine and gearbox support - VAS 6095A-
7. Securing to engine and gearbox support 157

Secure gearbox on engine and gearbox support

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

and gearbox support
♦ Support clamp - VW 313-
♦ Gearbox support - T10108-

– Set bevel box or front differential lock onto hole number -4-
-arrow- in gearbox support - T10108- .
A - Place nuts M12 x 10 (qty. 4) between bevel box and gearbox
support .
– Then, align bevel box or front differential lock with remaining
3 holes, and secure it.
7. Securing to engine and gearbox support 159

8 Gear oil circuit

⇒ “8.1 Assembly overview - gear oil circuit”, page 160
⇒ “8.2 Removing and installing gear oil cooler”, page 160
⇒ “8.3 Removing and installing gear oil filter”, page 163
⇒ “8.4 Removing and installing motor for auxiliary hydraulic pump
1 for gearbox oil V475 ”, page 164
8.1 Assembly overview - gear oil circuit
1 - Bleeder cap
2 - O-ring
❑ Renew
3 - Bolt
❑ 20 Nm
4 - Gear oil cooler
⇒ page 160
5 - Gearbox
⇒ page 70
6 - Bolt
❑ 8 Nm + 45°
❑ Renew
7 - Motor for auxiliary hydraulic
pump 1 for gearbox oil - V475-
⇒ page 164
8 - Seal
❑ Renew
9 - Gear oil filter
❑ Information about oil
and filter change
⇒ page 5
⇒ page 163
10 - O-ring
❑ Renew
❑ Lubricate with gear oil
11 - Filter housing
❑ 50 Nm
12 - Heat insulation
8.2 Removing and installing gear oil cooler


Removing
– Move selector lever to position “P”.
– If necessary, remove battery and battery tray ⇒ Electrical sys‐
tem; Rep. gr. 27 ; Battery; Removing and installing battery
tray .
Note

open carefully.

escaping coolant.
8. Gear oil circuit 161

– Clamp off coolant hoses to gear oil cooler with hose clamps
-3094- and remove. Loosen hose clips -arrows- to do this.
– Seal open lines and unions with suitable plugs -1- from engine
bung set - VAS 6122- .
Caution
No coolant must be allowed to drip into gearbox!
– Cover gearbox with cloths to catch any escaping coolant.
– Unscrew bolts -arrows- and remove gear oil cooler -A-.
Installing
♦ Renew O-rings -arrows- after each removal.
♦ Coat O-rings with gear oil to prevent pinching of rings during
assembly.
♦ If sealing surface on gear oil cooler is damaged, it must be
renewed.
– Carefully remove strainer -1- of oil cooler with a screwdriver

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

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

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

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

Renew missing or damaged heat insulation -1-.
Installing
• Renew O-ring after removal.
– Insert filter element -1- with intake collar -arrow- into gearbox.
– Tighten filter housing.
– Install battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Exploded view - battery .
tion .
Specified torques
♦ Filter housing to gearbox
♦ Selector cable support bracket to gearbox
⇒ “3.1 Assembly overview - selector mechanism”, page 46
8.4 Removing and installing motor for auxil‐

iary hydraulic pump 1 for gearbox oil -
V475-
♦ Puller - T10530-
Removing


Vehicles with all-wheel drive:
– Remove bevel box ⇒ page 35 .
Vehicles with front differential lock:
– Remove front differential lock ⇒ page 174 .
– Remove bolts -arrows- (Shown on removed gearbox)
– Insert puller - T10530- in hole.

– Turn knurled nut -2- clockwise until puller is fixed in position.
– Using puller - T10530- , carefully pull out pump motor to one
side horizontally.
Installing
– Renew seal
– Push pump motor evenly into housing by hand.
– Tighten pump motor.
Vehicles with all-wheel drive:
Vehicles with front differential lock:
– Install front differential lock ⇒ page 178 .
– Top up gear oil ⇒ page 171 , and check gear oil level
⇒ page 168 .
Specified torques
♦ ⇒ “8.1 Assembly overview - gear oil circuit”, page 160

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


♦ Oil filling adapter - VAS 6262 A- with adapter - VAS 6262/1-
♦ If necessary: adapter - VAS 6262/6- or adapter - VAS 6262/7-
♦ Genuine 1 litre oil bottle, dual clutch gearbox oil; part number
⇒ Electronic Parts Catalogue
♦ Vehicle diagnostic tester

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

Measure length of breather pipe attached to adapter for filling oil

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

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

♦ ⇒ “9.2 Tools for gear oil change”, page 166
Test conditions
• Gearbox not in emergency running mode.
• Vehicle is placed on a four-pillar lifting platform or above an
assembly pit to ensure it is in total horizontal position.
• Selector lever in position “P”.
• The parking brake button has been pulled to activate the elec‐
tromechanical parking brake.
• The extraction hoses of a switched-on exhaust extraction sys‐
tem are connected.
• Engine running at idling speed.
• Air conditioning system and heater switched off.
Reading gear oil temperature
♦ The gear oil level changes depending on the gear oil temper‐
ature: if the gear oil temperature is too low, too much gear oil
may be filled; if the gear oil temperature is too high, an insuf‐
ficient amount of gear oil may be filled.
♦ An improper gear oil level impairs the function of the gearbox.
♦ At start of work, the oil temperature must not be above 30°C.
If necessary, allow the gearbox to cool down.
♦ Test temperature: 35 … 45°C
– Connect vehicle diagnostic tester -arrow- and identify vehicle
in Guided Functions .

– Select Dual clutch gearbox .

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

• Wear protective goggles.
• Wear acid-resistant gloves
– Place used oil collection and extraction unit - VAS 6622A- be‐
low gearbox.
• Engine is running at idling speed with selector lever in “P”.
– Unscrew inspection plug -arrow-.
9. Gear oil 169

• The accumulated gear oil flows out of the overflow pipe

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

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

• If some gear oil still escapes at a gear oil temperature of be‐
tween 35 and 45°C (caused by the increasing temperature),
the gear oil level is OK.
• Irrespective of the gear oil level a small gush of oil escapes
from the overflow pipe every 30 seconds due to the cooling oil
pulses for supplying the multi-clutch. This is not relevant for
determining the gear oil level.
• Do not re-use gear oil which has escaped.
– If the gear oil level is OK, tighten the overflow pipe and com‐
plete the work sequence ⇒ page 171 .
Fill with gear oil
Caution
Gearbox damage from overfilling.

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

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

– Screw adapter for oil filling - VAS 6262 A- into inspection plug
opening hand-tight.
– Hold bottle with adapter for oil filling - VAS 6262 A- as high as
possible over the dual clutch gearbox, and allow the gear oil
to flow into the dual clutch gearbox.
– To check, if the dual clutch gearbox has been filled sufficiently,
disconnect the quick-release coupling on adapter for oil filling
- VAS 6262 A- at regular intervals, and seal the hose with your
finger or a clean plug.
• The accumulated gear oil flows out of the overflow pipe
-arrow 2-.
• Irrespective of the gear oil level there is always a slight amount
of gear oil which escapes.
• If some gear oil still escapes at a gear oil temperature of be‐
tween 35 and 45°C (caused by the increasing temperature),
the gear oil level is OK.
• Irrespective of the gear oil level a small gush of oil escapes
from the overflow pipe every 30 seconds due to the cooling oil
pulses for supplying the multi-clutch. This is not relevant for
determining the gear oil level.
• Do not re-use gear oil which has escaped.
• Check the gear oil temperature on the vehicle diagnostic test‐
er , while filling gear oil. If 45°C are exceeded, stop filling gear
oil, and allow the gearbox to cool down.
– If the gear oil level is OK, perform the required measures for
completing the work sequence ⇒ page 171 .
Concluding measures
• Renew seal -arrow- for inspection plug.
– Unscrew adapter for oil filling - VAS 6262 A- from gearbox.
– Tighten overflow pipe.
– Tighten inspection plug -arrow-.

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

9. Gear oil 171

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

Test conditions
• Gearbox not in emergency running mode.
• Selector lever in position “P”.
• The parking brake button has been pulled to activate the elec‐
tromechanical parking brake.
• Engine is not running.
Drain gear oil
insulation .
Caution
Risk of injury to eyes and hands from escaping oil.

• Wear protective goggles.
low gearbox.
– Unscrew inspection plug -arrow-.
• The accumulated gear oil flows out of the overflow pipe.
– Remove overflow pipe and allow gear oil to drain.
– Remove oil drain plug -arrow- from mechatronic unit.

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

Fill with gear oil

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

– Screw dual clutch gearbox oil bottle onto adapter for oil filling
- VAS 6262 A- .
• Use adapter - VAS 6262/6- if necessary.
– Screw adapter for oil filling - VAS 6262 A- into inspection plug
opening hand-tight.
– Hold bottle with adapter for oil filling - VAS 6262 A- as high as
possible over the dual clutch gearbox, and allow 6 l of gear oil
to flow into the dual clutch gearbox.
– Start engine and allow it to run at idling speed.
– Press brake and shift through all selector lever positions “P,
R, N, D/S” at idling speed, leaving each position engaged for
about 3 seconds.
– Switch selector lever to “P” position.
– Do NOT switch off engine.
– Then, check oil level and top up as necessary ⇒ page 168 .
Specified torques
♦ ⇒ “9.1 Overview of oil drain and inspection plugs”, page 166
♦ Assembly overview - noise insulation ⇒ General body repairs,
exterior; Rep. gr. 66 ; Noise insulation; Assembly overview -
noise insulation .
9. Gear oil 173

10 Front differential lock

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

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


♦ Socket - T10107 A-
♦ Bracket - T10533/2-
♦ Bolt - T10533/4-
Removing:
height.
10. Front differential lock 175

Note
– Step on the brake pedal while a 2nd mechanic loosens the

right drive shaft bolt -arrow-.
sulation .
– If fitted, remove heat shield -1- for drive shaft -arrows- ⇒ Run‐
ning gear, axles, steering; Rep. gr. 40 ; Drive shaft .
Caution
Risk of damage to flexible joint.

♦ Observe ⇒ Rep. gr. 26 ; Emission control; Assembly
overview - emission control .
– Remove front exhaust pipe from engine and tie it up ⇒ Rep.

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

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

and oil temperature sender - G266- .

– Unscrew pendulum support bolts -1- from gearbox.

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

To do this, use an M8 x 30 bolt -1-.
– Bolt bracket -A- to gearbox using bolt - T10533/4- -C-.
– Bolt engine support -B- to subframe using an M8 bolt.
– Tighten bolts by hand.
– Push engine with engine support - T50015- as far forwards as
possible.
– Ensure that coolant hoses are not trapped between engine
and radiator.
– Unscrew securing bolt for right flange shaft using socket . To

do this, screw 2 bolts into flange and counterhold flange shaft
with a lever.
Renew countersunk bolt after removal.
– Unscrew upper securing bolts -arrows- for securing front dif‐

ferential lock to gearbox.

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

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

– Push front differential lock completely onto gearbox. When
doing this, guide flange shaft/front differential lock input shaft
splines centrally together with differential. Turn flange shaft if
necessary.
– If splines are correctly positioned and shafts are centred, then
the front differential lock will slide to stop against gearbox.
– All cable ties which were opened or cut during removal must
be renewed at the same points.
Note
Do not use securing bolts to pull the front differential lock against
the gearbox. Otherwise the front differential lock will cant and the
bolt holes may break off.
– Screw in lower securing bolts -arrows- for front differential lock

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

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

and tighten them. Specified torque: ⇒ Item 5 (page 174)
– Secure flange shaft using new countersunk bolt. Specified tor‐

que: ⇒ Item 2 (page 174)
– Remove engine support - T50015A- .
– Install new bolts -1- securing pendulum support to gearbox ⇒

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

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

J647- .

– If present, install heat shield -1- for drive shaft -arrows- ⇒
Running gear, axles, steering; Rep. gr. 40 ; Drive shaft .
– Top up gear oil in front differential lock ⇒ page 189 .
– Assemble exhaust system ⇒ Rep. gr. 26 ; Exhaust pipes/
tion .
10.4 Removing and installing differential lock

control unit - J647-
Removing
– Switch off ignition.
Depending on equipment version, the axle differential lock control
unit - J647- is covered by the noise insulation on some vehicles.
– In this case, remove noise insulation ⇒ General body repairs,
exterior; Rep. gr. 66 ; Noise insulation; Assembly overview –
noise insulation .

– Pull off connectors -1- and -2-.

– Unscrew bolts -arrows-, and remove axle differential lock con‐
trol unit - J647- .
Installing
Install in reverse order but note following:
– Test operation ⇒ page 203 .
Specified torques
♦ Axle differential lock control unit - J647- to front differential lock
⇒ page 202

35 – Gears, shafts
1 Currently, no repairs can be made to
gears and shafts
182 Rep. gr.35 - Gears, shafts

39 – Final drive - differential

1 Gear oil
⇒ “1.1 Checking gear oil level”, page 183
⇒ “1.2 Draining and filling gear oil”, page 183
1.1 Checking gear oil level

• The bevel box is bolted to side of the gearbox and has its own
oil supply.
• Specifications for gear oil ⇒ Electronic Parts Catalogue
• Renew bolt for oil filler hole after each removal.
insulation .
– If necessary, unscrew nuts -arrows-, and detach heat shield
for right drive shaft.
– Unscrew oil filler plug -1-.

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

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

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

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

catalogue
♦ Safety goggles
Draining
• Renew oil drain plug and bolt for oil filler hole after each re‐
moval.
insulation .
low gearbox.
– Unscrew oil drain plug -2-, and drain gear oil.
– Screw in new oil drain plug -2-.
Replenishing
– If necessary, unscrew nuts -1-, and detach heat shield for right
drive shaft.
– Route hose of charging device for Haldex coupling 2 - VAS
6291 A- through engine compartment.
1. Gear oil 185

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

– Engage angled piece of filling device for Haldex coupling 2 -
VAS 6291 A- with adapter for oil filling -VAS 6291/3- .
• Do not allow hose to sag.
– Ensure that valve -arrow- is closed.

– Screw oil reservoir -1- onto charging device for Haldex cou‐
pling 2 - VAS 6291 A- .
• In the case of some oil bottles, the adapter -VAS 6262/6- must
be used as well.
– Open valve -arrow-, and hold up oil container as shown in il‐
lustration.

• The bevel box will now be filled.

• If bevel box has been properly filled, oil will emerge from
adapter for oil filling -VAS 6291/3- .
– If gear oil has emerged from adapter for oil filling - VAS
6291/3- , position oil container so that surplus oil can run back
into it.
– When no more oil flows back, remove filling device for Haldex
coupling 2 - VAS 6291 A- .
– Screw in »old« oil drain plug and tighten slightly.
– Start engine, engage gear, and allow gearbox to turn for ap‐
prox. 2 minutes.
– Turn off engine and unscrew plug from oil filler hole.
– Check oil level, if necessary top up gear oil again to lower edge
of filler hole.
– Tighten new oil filler plug.
• Clean bevel box thoroughly to remove any remains of the
emerged oil.
– Install heat shield for drive shaft ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40 ; Drive shaft; Removing and installing heat
shield for drive shaft .
Specified torques
1- Oil filler plug
• Renew after removal
• 15 Nm
2- Oil drain plug

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

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

2 Oil for front differential lock

⇒ “2.1 Checking oil level for front differential lock”, page 188
⇒ “2.2 Draining and filling oil for front differential lock”,
page 189
2.1 Checking oil level for front differential

lock
Oil for front differential lock is available as a replacement part ⇒
Electronic parts catalogue (ETKA) .
♦ Temperature gauge - VAS 6519-
♦ Used oil collector and extractor - V.A.G 1782-
♦ Not illustrated: Torque wrench - V.A.G 1331-

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

Check oil level.

– Unscrew oil filler plug -arrow-.
Always renew oil filler plug after removing.
• Oil level is correct when front axle differential lock is filled to
lower edge of filler hole.
– Screw in new oil filler plug -arrow- and tighten it to specified
torque.
– If the oil level is not correct, top up oil ⇒ page 189 .
Specified torque
♦ Oil filler plug ⇒ page 202
2.2 Draining and filling oil for front differen‐

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

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

mercially available
♦ Funnel, commercially available
• Observe safety data sheet.
• Vehicle level.
• The differential lock on the front axle is in the installation po‐
sition
Caution
Risk of injury
– If fitted, remove noise insulation ⇒ General body repairs, ex‐

terior; Rep. gr. 66 ; Noise insulation; Assembly overview -
noise insulation .
– Position used oil collection and extraction unit - V.A.G 1782-
under final drive.
– Use funnel, flexible - VAS 6675- to drain the oil.
– Fit the funnel is such a way that no oil gets onto the subframe.
– Unscrew oil drain plug -arrow- of front differential lock.

– Completely drain oil for front differential lock .

The illustration shows an example of how to use the funnel.
Note
If the oil is not going to be reused, observe the regulations for

disposal.
– Screw in new oil drain plug -arrow- (⇒ previous illustration),

and tighten it to specified torque.
tion .
Specified torque
♦ Oil drain plug ⇒ page 202
Replenishing oil for front differential lock
– Renew oil filler plug after each removal.
• Vehicle level.
– Position used oil collection and extraction unit - V.A.G 1782-

under front differential lock.
– Use a hose (approx. 1.50 m long, external diameter 15 mm),
commercially available and a funnel, commercially available
for filling oil.
– Route hose -A- through engine compartment.
– Clean area around oil filler plug -arrow- of front differential lock.
– Cover surrounding components.
– Unscrew oil filler plug -arrow-.
2. Oil for front differential lock 191

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

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

– Top up oil until oil escapes between hose and filler hole.
– Remove hose . Excess oil may escape while doing so.
• Oil level is correct when front differential lock is filled to lower
edge of filler hole.
– Screw in new oil filler plug -arrow- and tighten it to specified

torque.
– Clean area around oil filler plug -arrow- of front differential lock.
If necessary, clean surrounding components.
Specified torque
♦ Oil filler plug ⇒ page 202

3 Oil seals
⇒ “3.1 Overview of fitting locations - seals”, page 193
⇒ “3.2 Renewing left seal”, page 193
⇒ “3.3 Renewing right oil seal”, page 196
⇒ “5.5 Renewing seals for front differential lock”, page 205
3.1 Overview of fitting locations - seals
1 - Seal, right
❑ Renewing ⇒ page 196
2 - Seal
❑ For selector shaft
3 - Left seal
3.2 Renewing left seal

3. Oil seals 193

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

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

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

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

hole drilled in oil seal. Do not screw in sheet metal screw too
far to avoid damaging bearing behind it.
– Place drip tray for workshop hoist - VAS 6208- below gearbox.
– Pull out oil seal using puller - T10055- and adapter -
T10055/2- .
Make sure no metal chips get into gearbox and into opening for
drive shaft. Vacuum out metal chips first if necessary.
– Carefully remove cloths and make sure that no metal chips get
into gearbox.
– Carefully clean gearbox and opening for drive shaft.
If only the sheet metal ring could be pulled out, carefully lever out
rest of seal with a screwdriver.
Installing
doing this:
Before installing the seal, apply sealing grease for oil seal - G 052
128 A1- to sealing lips and cavity, and apply oil to outer circum‐
ference.
Installation position:
Open side of oil seal faces gearbox.
– Drive oil seal in to stop with thrust piece - T10457- . Do not

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

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

- N 052 735 Y0- .
– Install left drive shaft ⇒ Running gear, axles, steering; Rep.
3.3 Renewing right oil seal

⇒ “3.3.1 Renewing right seal, vehicles with front-wheel drive”,
page 196
⇒ “3.3.2 Renewing right oil seal - all-wheel drive vehicles”,
page 198
3.3.1 Renewing right seal, vehicles with front-

wheel drive
♦ Puller - T10055-
♦ Not illustrated: thrust piece - T40372-

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

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

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

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

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

3.3.2 Renewing right oil seal - all-wheel drive

vehicles
♦ Extractor hook - T20143-
♦ Sealing grease - G 052 128 A1-

low gearbox.

– Lever out oil seal on dual clutch gearbox using extractor tool
- T20143/1- or - T20143/2- .
– Moisten new oil seal with gear oil along its outer circumfer‐
ence.
– Fill space between sealing lip and dust lip -arrow- with sealing
grease - G 052 128 A1- .
– Carefully drive in oil seal to stop using thrust piece - T10049- .

3. Oil seals 199

4 Differential
⇒ “4.1 Removing and installing right flange shaft”, page 200
4.1 Removing and installing right flange

shaft
⇒ “4.1.1 Removing and installing flange shaft - vehicles with all-
wheel drive”, page 200
4.1.1 Removing and installing flange shaft -

vehicles with all-wheel drive
♦ Puller - T10037-
♦ Socket - T10107A-
Removing

– Unscrew nuts -arrows-, and remove heat shield for right drive
shaft.
low gearbox.
– Remove bolt for right flange shaft using socket - T10107 A- by
screwing 2 bolts into flange and counterholding flange shaft
with an assembly lever.
– Pull out flange shaft -1- using puller - T10037- .

-A- = M10 x 25 bolts
Note
Use puller - T10037- to remove the flange shaft to avoid damage

to bearings of the flange shaft.
In the upper area of the bevel box, there is a hexagon bolt -B- with
an M 8 stud.
– To support the puller fit the thrust piece - T10135- onto this
hexagon bolt.
– Use spindle -C- to align puller parallel to flange.
– Pull out flange shaft.
Installing
– Carefully drive in flange shaft while turning it.
– Bolt on flange shaft.
– Check gear oil level ⇒ page 183 .
Specified torques
♦ Flange shaft bolt: 25 Nm
♦ Drive shaft; Assembly overview - drive shaft ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Drive shaft; Assembly overview
- drive shaft
4. Differential 201
5 Components of front differential lock

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

2 - Seal
❑ For flange shaft in front
differential lock
❑ Renew with front differ‐
ential lock removed
⇒ page 211
3 - Support washer
❑ Not a replacement part
4 - Seal
❑ Between front differen‐
tial lock and gearbox
❑ Renew with front differ‐
ential lock removed
⇒ page 209
5 - Bolts
❑ 9 Nm
6 - Pump for front differential
lock - V181-
⇒ page 203
7 - O-ring
❑ For pump for front differ‐
ential lock - V181-
❑ Moisten O-rings with oil
for front differential lock
8 - Transverse lock-up control
unit - J647-
⇒ page 180
9 - Bolts
❑ 9 Nm
10 - Ball bearing
❑ For flange shaft in front differential lock
❑ Renew with front differential lock removed ⇒ page 212

11 - Retaining ring
❑ For ball bearing
12 - Seal
❑ For flange shaft
❑ Renew with front differential lock installed ⇒ page 205
13 - Flange shaft
❑ Removing and installing ⇒ page 208
14 - Retaining ring
❑ For flange shaft in front differential lock
❑ Renew after removal of flange shaft
15 - Bolt
❑ With M8 stud
❑ 40 Nm
16 - Bolt
❑ With M8 stud
❑ 40 Nm
17 - Oil drain plug
❑ With O-ring
❑ Moisten O-ring with oil for front differential lock
❑ 15 Nm
18 - Hydraulic fluid filler plug
❑ With O-ring
❑ Moisten O-ring with oil for front differential lock
❑ 15 Nm
5.2 Checking function
Note
If individual parts such as the pump or control unit are renewed,

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

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

Removing
– Switch off ignition.
On some vehicles, pump for front differential lock - V181- is con‐
cealed by noise insulation.
– In this case, remove noise insulation ⇒ General body repairs,
exterior; Rep. gr. 66 ; Noise insulation; Assembly overview –
noise insulation .
– Pull off wiring harness -arrow- for pump for front differential
lock .
– Unscrew bolts -1- of pump for front differential lock -2-.
– Pull out pump for front differential lock -2-.
Installing
Install in reverse order but note following:
– If necessary, renew O-rings -1- and -2- and lightly coat with oil
for front differential lock .

– Push in pump for front differential lock -2- as far as stop. When
doing so, observe routing of wiring harness.
– Tighten bolts -1- to specified torque.
– Push electrical connector -arrow- for pump for front differential
lock onto axle differential lock control unit - J647- .
– Check level of oil for front differential lock and top up if nec‐
essary ⇒ page 188 .
– Test operation ⇒ page 203 .
Specified torque
Pump for front differential lock ⇒ page 202
5.4 Removing and installing coupling for

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

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


equipment required

♦ Multi-purpose tool - VW 771 A-

♦ Hexagon key extension, 8 mm - 3247-
♦ Supplementary set for engine and gearbox support - VW 540/1
B-
♦ Drip tray - V.A.G 1306-
♦ or drip tray for workshop hoist - VAS 6208-
♦ Sealing grease - G 052 128 A1-
Removing
The right drive shaft will be removed in a later step.
– While vehicle is still standing on its wheels, loosen front right
flange bolt -arrow- by a maximum of 90°, otherwise the wheel
bearing will be damaged. ⇒ Running gear, axles, steering;
– If fitted, remove noise insulation ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Noise insulation; Assembly overview -
noise insulation .
– Drain oil from front differential lock ⇒ page 189 .
– Remove drive shaft heat shield -arrows- ⇒ Running gear,

axles, steering; Rep. gr. 40 ; Drive shaft .
– Unscrew right flange shaft bolt -arrow- using socket . To do

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

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

for engine and gearbox support - VW 540/1 B- .
-a- = washer
– Bolt flange shaft to multi-purpose tool - VW 771- and pull out.
Note
♦ The flange shaft is secured with a retaining ring -arrow-.

♦ Check if the retaining ring -arrow- is present.
If necessary, remove the retaining ring from the area of the seal
-1- or of the ball bearing -2-.
– Lever out flange shaft seal -1- using assembly lever.
Installing
– Lightly oil outer circumference of new oil seal.
– Drive in new oil seal to stop, being careful not to cant oil seal.

– Fill space between sealing lip and dust lip -arrow- with sealing
grease - G 052 128 A1- .
Renew retaining ring -arrow-.

– Push in flange shaft to stop by hand.
– Drive in flange shaft, being careful not to cant it.
– Tighten flange shaft with countersunk bolt.
– Top up gear oil in front differential lock ⇒ page 189 .
– If present, install drive shaft heat shield -arrows- ⇒ Running

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

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

Removing
– Secure front differential lock on engine and gearbox support
⇒ page 158 .
As opposed to the scenario shown in the illustration the flange
shaft does not need to be removed.
– Lever out seal.
• Do not damage the plastic container -A- and the support wash‐
er -B-.
The support washer -B- is located right below the seal.
Installing
• When installing the seal, make sure that support washer -B-
is inserted ⇒ page 202 .
– Fill half of space between sealing lip and dust lip -arrow- with
sealing grease - G 052 128 A1- .
– Drive in new seal to stop, being careful not to cant seal.

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

5.5.3 Renewing seal for right flange shaft in

front differential lock
♦ Multi-purpose tool - VW 771-
♦ Extractor hook - VW 771/37-
Removing
– Secure front differential lock to engine and gearbox support
⇒ page 158 .
– Remove flange shaft ⇒ page 208 .

The seal is located in the front differential lock before the roller
bearing -A-.
Caution
Do not damage the roller bearing -A- when removing the seal.
Installation position of seal:
105 mm below upper edge/hollow shaft
– Pull out seal using multi-purpose tool - VW 771- and extractor

hook - VW 771/37- .
• Push extractor hook - VW 771/37- firmly into seal
-direction of arrow-.
Installing
sealing grease - G 052 128 A1- .
Installation position of seal:

• Open side -arrow- faces towards inside of front differential lock
(towards front differential lock).
– Drive in new seal to stop, being careful not to cant seal.

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


♦ -1- internal puller, e.g. KUKKO 21-5 - VAS 251 611-
♦ Adapter from sliding hammer -Kukko 22-0-1-

♦ Press tool - VW412-
♦ Thrust piece - VW473-
♦ Thrust plate - VW401-

♦ Thrust plate - VW402-
Removing

– Secure front differential lock on engine and gearbox support

⇒ page 158 .
– Remove flange shaft ⇒ page 208 .
– Lever out flange shaft oil seal with assembly lever.
– Remove retaining ring in front of ball bearing ⇒ page 202 .
– Pull out ball bearing for flange shaft.
A - Internal puller e.g. KUKKO 21-5 - VAS 251 611-
B - Adapter from sliding hammer -Kukko 22-0-1-
Installing
• The smaller end of thrust piece - VW473- points towards ball
bearing.
• Fit press tool - VW473- centrally onto ball bearing.
• Do not damage the plastic container -A-.
– Press in ball bearing for flange shaft to stop.
– Secure ball bearing with new retaining ring.
– Install seal for flange shaft ⇒ page 205 .
– Install flange shaft ⇒ page 208 .

6 Components of bevel box

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

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

(Seals, flange shaft mount, output flange mount in bevel box)
1 - Seal
❑ Between bevel box and
bevel box
❑ Replacing with bevel
box removed
⇒ page 219
2 - Bevel box
3 - Oil drain plug
❑ With captive seal
❑ 15 Nm
❑ 15 Nm
5 - Seal
❑ For right flange shaft
❑ Renewing with gearbox
and bevel box installed
⇒ Rep. gr. 39 ; Oil
seals; Renewing right oil
seal
6 - Breather pipe
❑ To vent bevel box
❑ Press in until stop is
reached
6. Components of bevel box 215

7 - Cap
8 - Breather pipe
❑ Allocation ⇒ Electronic parts catalogue (ETKA)
10 Nm
9 - Bolt
❑ 5 Nm
10 - Shield
❑ Not fitted in all bevel boxes
❑ The outline may differ from that shown in the diagram.
11 - Right flange shaft
❑ Removing and installing ⇒ Rep. gr. 39 ; Oil seals; Renewing right oil seal
12 - Seal
❑ To renew, remove needle bearings (polygon bearings) ⇒ Rep. gr. 39 ; Components of bevel box
13 - Needle bearing (polygon bearing)
❑ Needle bearing (polygon bearing) is difficult to turn with flange shaft removed The fact it is difficult to
move does not mean that the bearing is defective. An acoustic test can only be performed with the
bearings installed.
❑ Inspect for signs of damage to bearings, such as cracking in outer race, and renew if necessary.
❑ Renewing ⇒ Rep. gr. 39 ; Components of bevel box
14 - Locking ring
❑ For needle roller bearing (polygon bearing)
❑ Insert in circumferential groove in stub shaft
15 - Hexagon nut
❑ Install using locking fluid - D 000 600-
❑ 480 Nm
16 - Output flange
17 - Cover
❑ Not fitted in all bevel boxes
❑ Renew if damaged
❑ Engage with output flange
18 - Shim
❑ Redetermine if output flange is renewed ⇒ page 241 .
19 - Seal
❑ For output flange
❑ Replace only with bevel box removed ⇒ page 220
20 - Tapered roller bearing inner race
❑ No replacement part available for this component

21 - Bolt
❑ 25 Nm
22 - Pinion housing
❑ With shaft bevel gear and outer race/tapered roller bearing
❑ No replacement parts available for these components
❑ Carefully lever off and drive in alternately
❑ Observe bolt holes; pinion housing fits only in one position.
23 - O-ring
❑ To renew, unscrew bolts and carefully lever off pinion housing at projecting webs on outside edge.
❑ Do not remove hexagon nut and output flange.
24 - Shim
❑ Observe bevel box bolt bores; shim only fits in one position.
25 - Cap
❑ Drive in to stop with spacer tube - VW 540 1B- .
6.1.2 Assembly overview - components of bevel box, “0CN”

(Seals, flange shaft mount, output flange mount in bevel box)
1 - Seal
❑ Between bevel box and
bevel box
❑ Replacing with bevel
box removed
⇒ page 219
2 - Bevel box
3 - Oil drain plug
❑ 15 Nm
❑ 15 Nm
5 - Seal
❑ For right flange shaft
❑ Renewing with gearbox
and bevel box installed
⇒ Rep. gr. 39 ; Oil
seals; Renewing right oil
seal
6 - Breather pipe
❑ Press in until stop is
reached
Volkswagen Technical Site: http://vwts.ru http://vwts.info 6. Components of bevel box 217

7 - Cap
8 - Right flange shaft
❑ Removing and installing ⇒ Rep. gr. 39 ; Oil seals; Renewing right oil seal
9 - Seal
❑ To renew, remove needle bearings (polygon bearings) ⇒ Rep. gr. 39 ; Components of bevel box
10 - Needle bearing (polygon bearing)
❑ Needle bearing (polygon bearing) is difficult to turn with flange shaft removed The fact it is difficult to
move does not mean that the bearing is defective. An acoustic test can only be performed with the
bearings installed.
❑ Inspect for signs of damage to bearings, such as cracking in outer race, and renew if necessary.
❑ Renewing ⇒ Rep. gr. 39 ; Components of bevel box
11 - Locking ring
❑ For needle roller bearing (polygon bearing)
❑ Insert in circumferential groove in stub shaft
12 - 12-point nut
❑ Install using locking fluid - D 000 600-
❑ Secure nut at three opposing points by peening.
❑ 350 Nm +_15 Nm
13 - Output flange
14 - Shim
❑ Redetermine if output flange is renewed ⇒ page 241 .
15 - Seal
❑ For output flange
❑ Replace only with bevel box removed ⇒ page 232
16 - Tapered roller bearing inner race
17 - Bolt
❑ 38 Nm
18 - Pinion housing
❑ With shaft bevel gear and outer race/tapered roller bearing
❑ No replacement parts available for these components
❑ Carefully lever off and drive in alternately
❑ Observe bolt holes; pinion housing fits only in one position.
19 - O-ring
❑ To renew, unscrew bolts and carefully lever off pinion housing at projecting webs on outside edge.
❑ Do not remove hexagon nut and output flange.
20 - Shim
❑ Observe bevel box bolt bores; shim only fits in one position.

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

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

bevel box and gearbox
♦ Removal tool - T20143-
♦ Sealing grease
♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
– Remove bevel box ⇒ Rep. gr. 34 ; Bevel box; Removing bevel
box .

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

- T20143/2- .
sealing grease .
– Drive in seal to stop.

– Install bevel box ⇒ Rep. gr. 34 ; Bevel box; Installing bevel
box .
– Check gear oil level in bevel box ⇒ Rep. gr. 39 ; Gear oil .
6.2.2 Renewing output flange oil seal, bevel

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


equipment required
♦ Support clamp - VW 313-

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

♦ Taper roller bearing puller - V.A.G 1582- with short sleeve

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

♦ Only for seal in pinion housing ⇒ page 227
♦ Extractor hook - VW 771/37-

♦ Seal located on output flange ⇒ page 229

♦ Press tool - VW 412-
♦ Thrust piece - VW 454-
♦ Installing sleeve - VW 455-
♦ Thrust plate - VW 401-
♦ or thrust plate - VW 402-
♦ 2 M 8 X 30 mm studs or guide pins M8 - T10273-
♦ Not required: pin - VW 460/2-
♦ Tube - 3296-

♦ Tube - 3296-
♦ Crankshaft seal installing tool - VW 204 B-
♦ Sealing grease
♦ Universal grease
♦ 2 x M10 x 30 bolts
♦ 4 x M12 x 10 nuts

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

– Fit bevel box on gearbox support - T10108- onto hole
-arrow- marked with the number -4-.
A - Lay nuts M12 x 10 (qty. 4) between bevel box and gearbox
support .
– Then align bevel box with remaining 3 holes and secure.
– Place drip tray underneath.
– Drain oil from bevel box.
Removing hexagon nut for output flange

– Lock output flange for bevel box with stop plate - T10108/1- .
Screw in M10 x 30 bolts -arrows- to do this.
A - 36 mm socket for 3/4" drive
– Swing bevel box so that output flange points upwards.

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

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

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

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

Removing seal
– Pull out seal -A- for output flange.

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

output flange:
Caution
Risk of damage to tapered roller bearing inner race.

● Pull off tapered roller bearing inner race using adapter -
V.A.G 1582/6- or adapter - V.A.G 1582/6A- .
● If tapered roller bearing inner race is damaged, bevel box
must be replaced.
– Fit thrust plate - 40-105- onto output flange.

– Pull inner ring/the tapered roller bearing off output flange using
tapered roller bearing puller .
Note
Adapter - V.A.G 1582/6- may be used in place of adapter - V.A.G

1582/6A- .
Installing seal and output shaft

– Cover pinion housing with a lint-free cloth.
– Clean residual locking fluid from thread of shaft bevel gear.
• If shim -2- was also removed when output flange was re‐
moved, it has to be reinserted in pinion housing.
• It assures bearing preload of shaft bevel gear -1- in pinion
housing.
– Lay existing tapered roller bearing inner race -3- in outer race
in bevel box.
– Lightly oil outer circumference of new seal -4- for output flange.
– Drive in new oil seal with thrust piece - T10049- .

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

– Lightly lubricate splines of output shaft with universal grease .

– Pull in output flange using two arm puller -A-.
A - Two-arm puller - VAS 251 001- , or e.g. two-arm puller - Kukko
20/10-
Please note the following:
• Use new or nearly new puller hooks!
• The output flange must not be canted.
• Fit puller hooks as far as they will go onto underside of pinion
housing.
• Take up slack on puller hooks fully with two arm puller
-arrows-.
• Puller hooks should not bend outwards.
• If necessary, halt pulling process, pull off output flange again
and restart pulling process.
Removing and installing output flange seal -arrow-:

Removing seal
• Bearing inner race/taper roller bearing must be removed in

order to remove output flange seal.
Caution

V.A.G 1582/13- .
must be replaced.

– Remove seal from output shaft.


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

pinion housing.
– Press in new oil seal flush.

• The larger diameter of crankshaft seal installing tool - VW 204
B- must face towards seal.
• Half-fill space between sealing lip and dust lip of seal with
sealing grease .
– Place pinion housing and tapered roller bearing inner race on
output flange.
– Press tapered roller bearing inner race ⇒ page 217 onto output
flange as far as it will go.
• The larger diameter of thrust piece - VW 454- must face to‐
wards output flange.
• Press in tapered roller bearing inner race only as far as it will
go.
• Do not expose the tapered roller bearing to higher forces than
necessary.

– Fit shim -2-, tapered roller bearing inner race -3- and pinion
housing -4- onto shaft bevel gear -1-.
• Always reinstall the existing shim -2-.
ing.
– Press output flange and pinion housing plus shaft bevel gear
together as far as they will go.
• Shoulder -arrow- of installing sleeve - VW 455- faces shaft
bevel gear.
– Screw in M 8 X 30 mm stud bolts = -A- or M8 guide bolts -

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

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

flange -2- slightly back and forth while doing so.
– Tighten securing bolts for pinion housing -2- cross-wise.
Coat thread of new hexagon nut with locking fluid D 000 600
– Tighten new hexagon nut for output flange ⇒ page 215 .
A - 36 mm socket for 3/4" drive
Measure radial run-out on output flange/shaft bevel gear.
Note
After the output flange nut has been tightened, the radial run-out
on the centring pin of the shaft bevel gear must be checked.
– Secure measuring tools with bolt -A- (M8 x 25) on bevel box.
– Fit dial gauge - VAS 6080- on centring pin of shaft bevel gear
-B- and set it to “0” with 1 mm preload.
– Turn output flange one full turn in -direction of arrow-.
– Read measured value on dial gauge.
• Max. radial run-out = 0.05 mm.
Specified torques
♦ ⇒ “6.1.1 Assembly overview - components of bevel box, 0AV /
0FV ”, page 215
6.2.3 Renewing output flange oil seal, bevel

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


equipment required

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

♦ Support rails - VW 457-

♦ Tube - 3296-
♦ Support plate - T10108/1-
♦ Taper roller bearing puller - V.A.G 1582- with short sleeve
♦ Grip tool - V.A.G 1582/13-

♦ Crankshaft seal installing tool - VW 204 B-

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

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

– Fit bevel box on gearbox support - T10108- onto hole
-arrow- marked with the number -4-.
A - Place nuts M12 x 10 (qty. 4) between bevel box and gearbox
support .
– Then align bevel box with remaining 3 holes and secure.
– Place drip tray underneath.
– Drain oil from bevel box.
– Release peened points -arrows- of twelve-point nut -A- from

indentations of output flange -B- by driving them inwards.
Unscrew twelve-point nut for output flange.

A - Socket, 34 mm - T50019-

– Swing bevel box so that output flange points upwards.

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

es -arrows- of pinion housing -A- and carefully lever off pinion
housing together with shaft bevel gear.
– Position output flange -A- evenly on support rails - VW 457-

-arrows-.
– Press shaft bevel gear off output flange -A-.
• Prevent shaft bevel gear and tapered roller bearing inner race
from falling down while doing so.
– Press output flange -A- out of pinion housing.

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

order to remove output flange seal.
Caution

V.A.G 1582/13- .
must be replaced.

– Remove seal from output shaft.

– Place existing bearing inner race/tapered roller bearing -1- in
pinion housing.
– Press in new oil seal flush.

• The larger diameter of crankshaft seal installing tool - VW 204
B- must face towards seal.
• Half-fill space between sealing lip and dust lip of seal with
sealing grease .
– Place pinion housing and tapered roller bearing inner race on
output flange.

– Press tapered roller bearing inner race ⇒ page 217 onto output
flange as far as it will go.
• The larger diameter of thrust piece - VW 454- must face to‐
wards output flange.
• Press in tapered roller bearing inner race only as far as it will
go.
• Do not expose the tapered roller bearing to higher forces than
necessary.
– Fit shim -2-, tapered roller bearing inner race -3- and pinion
housing -4- onto shaft bevel gear -1-.
• Always reinstall the existing shim -2-.
ing.
– Lightly lubricate splines of output shaft with universal grease .

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

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

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

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

– Tighten new 12-point nut for output flange ⇒ page 217 .
A - Socket, 34 mm - T50019-
– Secure twelve-point nut -A-

– in indentations (offset by 120°) of output flange -B- by peening
-arrows-.

Measure radial run-out on output flange/shaft bevel gear.
Note
After the output flange nut has been tightened, the radial run-out
on the centring pin of the shaft bevel gear must be checked.
– Secure measuring tools with bolt -A- (M8 x 25) on bevel box.
– Fit dial gauge - VAS 6080- on centring pin of shaft bevel gear
-B- and set it to “0” with 1 mm preload.
– Turn output flange one full turn in -direction of arrow-.
– Read measured value on dial gauge.
• Max. radial run-out = 0.05 mm.
Specified torques
♦ ⇒ “6.1.2 Assembly overview - components of bevel box, 0CN
”, page 217
6.3 Renewing output flange and redeter‐

mining thickness of shim
• The bevel box is removed.
Adjustment is only necessary if the output flange is renewed. Its
purpose is to re-establish the shaft bevel gear tapered roller bear‐
ing preloading.
Bevel box “0AV / 0FV”:
– Remove output flange and pull tapered roller bearing inner
race off output flange ⇒ page 220 .
Bevel box “0CN”:
– Remove output flange and pull tapered roller bearing inner
race off output flange ⇒ page 232 .


– Measure length of old and new output flange shafts and de‐
termine difference.
Example:
Old output flange 42.90 mm
New output flange 43.00 mm
Difference 0.10 mm
If the new output flange is longer, install a shim which is thinner
by the difference.
If the existing output flange is longer, install a shim which is thicker
by the difference.
Allocation ⇒ Electronic parts catalogue (ETKA)
Bevel box “0AV / 0FV”:
– Install output flange ⇒ page 220 .
Bevel box “0CN”:
– Install output flange ⇒ page 232 .

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What safety precautions must be observed when working on vehicles?

What safety precautions must be observed when working on vehicles?

What are the main components discussed in the workshop manual?

What are the main components discussed in the workshop manual?

Service

Service Department. Technical Information

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

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

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

1.1 General safety provisions

Risk of injury and accident by accidental engagement of gear

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

To prevent damage to the electronic components when dis‐

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

1.2 Safety measures when working on ve‐

Risk of injury due to automatic start of engine on vehicles with

1.3 Notes on tow-starting/towing

Danger of irreparable damage to gearbox.

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

1.4 Safety precautions when using testers

Risk of accident due to distraction and inadequate securing of

2 Rep. gr.00 - Technical data

To prevent damage to the electronic components when dis‐

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

2.1 Gearbox identification

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

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

4 Rep. gr.00 - Technical data

3.1 General information

3.2 Rules for cleanliness

3.3 General repair instructions

A number of general notes on the individual repair procedures,

3.4 Gaskets and seals

6 Rep. gr.00 - Technical data

3.5 Nuts and bolts

4.1 Allocation gearbox - engine

4.1.1 Golf SV 2015 ►

4.1.2 Golf 2017 ►

Dual clutch gearbox 0GC »all-wheel drive«

4.1.3 Golf Estate 2017 ►

Dual clutch gearbox 0GC »all-wheel drive«

4.1.4 Golf SV 2018 ►

8 Rep. gr.00 - Technical data Volkswagen Technical Site: http://vwts.ru http://vwts.info

4.1.5 Tiguan 2016 ►

Dual clutch gearbox 0GC »all-wheel drive«

4.2.1 Capacities - dual clutch gearbox

Lubricant Dual clutch gearbox oil

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

4.2.2 Capacities, front differential lock

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

4.2.3 Capacities, bevel box

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

10 Rep. gr.00 - Technical data

5.1 Overview of fitting locations - electrical

5.1.1 Overview of fitting locations - gearbox control

1 - Mechatronic unit for dual

5.1.2 Overview of fitting locations – electrical components, front differential lock

1 - Transverse lock-up control

12 Rep. gr.00 - Technical data