6-Speed Dual Clutch Transmission 02E

Service
Repair Manual
Golf Variant 2007 ➤
Golf Variant 2010 ➤
Jetta 2005 ➤
Jetta 2011 ➤
6-Speed Dual Clutch Transmission 02E
CBF CCT CBE CJAA CPLA CPP
Engine ID BRM BPY A A A A
Edition 09.2015
Service Department. Technical Information

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Service
List of Workshop Manual Repair Groups
Repair Group
00 - General, 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.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-Speed Dual Clutch Transmission 02E - Edition 09.2015
Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Brief Overview - Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 O-Rings, Gaskets and Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 DSG® Transmission Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.6 Bolts and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.7 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Troubleshooting, General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Transmission “Control Module Malfunction Behavior” Information . . . . . . . . . . . . . . . . . . . . 6
2.3 Fault Finding, Special Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Transmission Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Transmission Code, Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4 Engine Codes - Engine Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1 Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5 Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1 Overview - Dual Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2 Dual Clutch, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.1 Remove Clutch End Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.2 Clutch End Cover, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.3 Dual Clutch, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.4 Dual Clutch, Installing and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
34 - Controls, Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1 Electrical and Electronic Components, Component Locations in DSG® Transmission . . . . 33
1.1 DSG Transmission Mechatronic J743 , Removing and Installing, Transmission Installed
........................................................................ 34
1.2 DSG transmission Mechatronic J743 , Removing and Installing, Transmission Removed
........................................................................ 45
1.3 Transmission Input Speed Sensor G182 and Clutch Oil Temperature Sensor G509 ,
Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2 Transmission Fluid Cooler, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3 Oil Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4 Selector Shaft Lever Gasket, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5 Selector Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.1 Overview - Selector Mechanism, Vehicles through 02/2009 . . . . . . . . . . . . . . . . . . . . . . . . 62
5.2 Selector Lever Cable, Removing and Installing, through 02/2009 . . . . . . . . . . . . . . . . . . . . 64
5.3 Overview - Selector Mechanism, Vehicles from 03/2009 . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5.4 Selector Mechanism, Removing and Installing, Vehicles from 03/2009 . . . . . . . . . . . . . . . . 73
5.5 Selector Lever Cable, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.6 Selector Lever Cable, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.7 Selector Lever, Emergency Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.8 Selector Lever Handle, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.9 Button in Handle, Moving into Installation Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.10 Selector Mechanism, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Contents i
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6 Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and
Golf Wagon from MY 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6.1 Transmission, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6.2 Transmission, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
6.3 Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
7 Transmission, Removing and Installing, Jetta from MY 2011 . . . . . . . . . . . . . . . . . . . . . . 102
7.1 Transmission, Removing, Jetta MY 2011 with 2.0L 103 kW Diesel . . . . . . . . . . . . . . . . . . 102
7.2 Transmission, Installing, Jetta MY 2011 with 2.0L 103 kW Diesel . . . . . . . . . . . . . . . . . . . . 113
7.3 Transmission, Removing, Jetta MY 11, 2.0L 147 kW Gasoline Engine . . . . . . . . . . . . . . . . 115
7.4 Transmission, Installing, Jetta MY 11, 2.0L 147 kW Gasoline Engine . . . . . . . . . . . . . . . . 127
7.5 Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
8 Transmission, Transporting and Securing to Assembly Stand . . . . . . . . . . . . . . . . . . . . . . 131
9 Transmission Fluid and Transmission Fluid Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
9.1 Transmission Fluid Filter, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
9.2 Fluid Level, Checking and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
9.3 Fluid, Draining and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
10 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
35 - Gears, Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

1 No Repairs to Gears and Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
39 - Final Drive, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

1 Flange Shaft or Stub Shaft Seals, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
1.1 Component Location Overview - Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
1.2 Left Flange Shaft Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
1.3 Right Flange Shaft or Stub Shaft Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
3 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
ii Contents
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00 – General, Technical Data

1 General Repair Information
(Edition 09.2015)
⇒ “1.1 Tools”, page 1
⇒ “1.2 Transmission”, page 1
⇒ “1.3 Brief Overview - Guide”, page 2
⇒ “1.4 O-Rings, Gaskets and Seals”, page 3
⇒ “1.5 DSG® Transmission Fluid”, page 3
⇒ “1.6 Bolts and Nuts”, page 5
⇒ “1.7 Electrical Components”, page 5
This Repair Manual Was Developed for the Technician.
It should offer support and help. Using ELSA offers the ability to
submit comments and/or improvement suggestions to Volkswa‐
gen.
– Click the Feedback Button at the top in the menu toolbar.
More Information on the Dual-Clutch Transmission DSG®.
For more information about the transmission functions. Refer to
Self Study Program DSG transmission 02E.
1.1 Tools
A complete list of special tools and workshop equipment used in
the repair manual can be found at the beginning of each repair
section and in the “Special Tools and Workshop Equipment” fold‐
er.
Uncertainties often exist on smaller screws with lower tightening
specifications. The Torque Wrench 2-10Nm - VAG1783- can be
used on these screws.
1.2 Transmission
Always make sure that no dirt or contaminants enter an »open«
transmission. Any dirt that enters can cause transmission failure,
especially if the DSG Transmission Mechatronic - J743- and/or
the oil pump are »exposed«.
♦ Do not run the engine and do not tow the vehicle if the trans‐
mission cover is removed or if there is no transmission fluid
inside the transmission.
♦ Thoroughly clean the connection points and the area around
them first, and then loosen them.
♦ When installing the transmission, make sure the alignment
sleeves are seated correctly between the engine and the
transmission.
1. General Repair Information 1

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

so that they do not become contaminated. Use foil and paper.
Only use lint-free cloths.
♦ Only install clean components. Install original parts immedi‐
ately after removing them from their packaging.
♦ Carefully cover or seal opened components if repairs are not
performed immediately.
1.3 Brief Overview - Guide
1 - Filter
❑ Refer to
⇒ “9 Transmission Fluid
and Transmission Fluid
Filter”, page 132
❑ Information on changing
filter. Refer to
⇒ “1.5.2 Transmission
Fluid Filter, When To
Change ”, page 4 .
2 - Check Plug.
❑ Refer to
and Transmission Fluid
Filter”, page 132
❑ Near the pendulum sup‐
port
3 - Drain Plug
❑ Refer to
⇒ “1.5 DSG® Transmis‐
sion Fluid”, page 3
❑ This bolt is no longer in‐
stalled as of 09/2004.
The oil can be drained
through the check plug
4 - Transmission Fluid Cooler
❑ Refer to
Cooler, Removing and
Installing”, page 55
5 - DSG Transmission Mecha‐
tronic - J743-
❑ Refer to
⇒ “1 Electrical and Elec‐
tronic Components,
Component Locations in DSG® Transmission”, page 33
6 - Transmission Input Speed Sensor - G182- and Clutch Oil Temperature Sensor - G509-
❑ Refer to
⇒ “1 Electrical and Electronic Components, Component Locations in DSG® Transmission”, page 33 .
7 - Oil Pump
❑ Refer to ⇒ “3 Oil Pump, Removing and Installing”, page 57
8 - Clutch Cover for the DSG®
9 - Dual Clutch
❑ Refer to ⇒ “1 Overview - Dual Clutch”, page 15
2 Rep. Gr.00 - General, Technical Data

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1.4 O-Rings, Gaskets and Seals

♦ Replace the O-rings, seals and gaskets.
♦ Flange shaft and selector shaft seals are illustrated as shaft
seals.
♦ After removing the gaskets and seals, check the contact sur‐
faces on the housing or shaft for burrs resulting from removal
or damage.
♦ Before installing the seals, lightly oil the outer circumference
and fill the space between the sealing lips -arrow- halfway with
Grease - G 052 128 A1- .
♦ Only use DSG® transmission fluid. Other lubricants cause
malfunctions.
♦ The open side of the gaskets point toward the fluid to be sealed
in.
♦ After installing, check transmission fluid level and fill. Refer to
⇒ “9.2 Fluid Level, Checking and Filling”, page 133 .
1.5 DSG® Transmission Fluid

⇒ “1.5.1 Fluid Function”, page 3
⇒ “1.5.2 Transmission Fluid Filter, When To Change ”,
page 4
⇒ “1.5.3 Fluid and Fluid Level Troubleshooting”, page 4
⇒ “1.5.4 Transmission Fluid Drain and Check Plug A ”,
page 4
Shake the bottles before opening.
Fluid is available as an original part. Original part number. Refer
to the Parts Catalog.
The Quality of Transmission Fluid Is Crucial to Transmission
Function.
Do not mix additives into the transmission fluid. Do not fill with a
different transmission fluid.
Determine the correct fluid and other important information. Refer
to
page 4 .
The drained transmission fluid must not be used again.
Caution
Be very careful when handling transmission fluid. Dispose of

drained transmission fluid correctly.
1.5.1 Fluid Function

The fluid does not just »lubricate« the transmission.
Imagine: the filter also transports the finest differential abrasive
parts in both filters. The fluid makes sure the lubricating film does
not wear off the differential tooth flanks. At the same time, it acts
as a switch valve pressure medium to enable it to perform its
functions.
It also seals the selector lever and helps the synchronizer rings
when shifting gears. The fluid conserves and transports warmth

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and minimizes noise. The fluid performs many functions. The

DSG® transmission fluid fulfills many requirements.
To maintain this degree of performance, the filter on the trans‐
mission should be replaced during the oil maintenance service.
1.5.2 Transmission Fluid Filter, »When To

Change«
The transmission fluid filter does not need to be changed in every
case.
Do Not Replace the Filter If
♦ The transmission fluid cooler or its O-rings were replaced and
no coolant has entered the transmission fluid.
♦ The selector shaft seal was replaced.
♦ The flange or stub shaft seal was replaced.
♦ Leaking Mechatronic covers, multi-plate clutch or oil pump
were replaced.
♦ The Transmission Input Speed Sensor - G182- with Clutch Oil
Temperature Sensor - G509- was replaced.
The Filter Must Be Replaced If
♦ The 60,000 km maintenance interval was reached.
♦ Coolant has entered the transmission fluid.
♦ Metal shavings were found in the transmission fluid.
♦ The clutch is burned or has a mechanical fault.
1.5.3 Fluid and Fluid Level Troubleshooting

Fluid and Fluid Level Troubleshooting
For more information regarding the fluid. Refer to
⇒ “1.5.1 Fluid Function”, page 3 . But the fluid cannot disappear
»without a trace«.
Fluid can only be missing if it has leaked from the transmission.
Transmission Lubricated
– Determine where the fluid has leaked out of the transmission.
Repair this leak first. Fill with new transmission fluid and make
sure the level is »correct«. Refer to
⇒ “9 Transmission Fluid and Transmission Fluid Filter”,
page 132 .
Filling the fluid »just in case« does not correct a malfunction. It
does not help to find the malfunction and it gives a false sense of
security.
1.5.4 Transmission Fluid Drain and Check

Plug -A-
Through transmission production date “09/20/2004”, transmis‐
sions were installed with two plugs.
Then the second plug was discontinued so that draining oil and
adjusting the oil level can both be done using the plug -A-.
A plastic overflow tube is located behind this plug (with 8 mm hex
socket head, tightening specification: 3 Nm). Its length deter‐
mines the fluid level in the transmission.

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1.6 Bolts and Nuts

♦ Loosen or tighten bolts and nuts on covers or housing diago‐
nally.
♦ The tightening specifications given apply to unoiled bolts and
nuts.
♦ Use a wire brush to clean the threads of the bolts that were
installed with locking fluid. Install the bolts with Locking Fluid
- AMV 185 101 A1- .
♦ Clean all threaded holes containing self-locking bolts, with a
thread tap to remove any locking fluid residue. Otherwise the
bolts could shear the next time they are removed.
♦ Always replace self-locking bolts and nuts.
1.7 Electrical Components

Almost everyone has been shocked at one time or another when
coming into contact with a metal object. The reason for this is the
build-up of static electricity in the human body. This charge can
damage the electrical components in the transmission and the
selector mechanism when touching them.
– Touch a grounded object, such as, a water pipe or a vehicle
hoist, before working on electrical components. Do not touch
the connector terminals directly.

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2 Troubleshooting
⇒ “2.1 Troubleshooting, General Information”, page 6
⇒ “2.2 Transmission Control Module Malfunction Behavior Infor‐
mation”, page 6
⇒ “2.3 Fault Finding, Special Information”, page 7
2.1 Troubleshooting, General Information

Before beginning any repair work, the cause of damage should
be determined using “Guided Fault Finding”.
Perform Guided Fault Finding using the Vehicle Diagnostic
Tester .
2.2 Transmission “Control Module Malfunc‐

tion Behavior” Information
The control module operates with highly developed software. This
software has the ability to execute electrical functions, monitor
and control within milliseconds. Everything modern transmission
electronics »have to offer« »is contained« in this control module.
This should also be kept in mind during troubleshooting.
However, no electronics can do what they were not designed to
do. Likewise, it is not possible to detect electronically where the
transmission housing is leaking and oil is escaping, for example.
However, it is possible to detect the effects of »low oil«. A failure
in “gear monitoring” would be recognized causing the control
module to respond that both clutches are open (no traction).
This should be known during troubleshooting and also when
working with the Volkswagen tester. It is possible that the cause
for the malfunction might not be found during Guided Fault
Finding .
In addition to the highly developed software, much has been done

to protect the transmission should there be a malfunction (safety
features). And so, when necessary, malfunctions are saved and
a replacement program is started.
Control Module Behavior During A Malfunction
If a component in the transmission malfunctions, the control mod‐
ule reacts with a replacement function. In order to protect the
transmission, there are four different kinds of malfunctions:
1- The malfunction is so minor that it is possible to continue
driving with a replacement program while maintaining driv‐
ing safety. The driver is not notified of this via the Selector
Lever Transmission Range Display - Y5- . The display
shows the selector lever position normally. If changes in
driving behavior can even be detected.
2- The individual lever positions blink in the Selector Lever
Transmission Range Display - Y5- . This signals to the driver
that the gear selection is currently not possible. Example:
Driving in reverse, lever in “R” and vehicle drives backwards.
If “D” is engaged in this situation, the letter “D” blinks in the
Selector Lever Transmission Range Display - Y5- . In this
case, the control module prevents 1st gear from being en‐
gaged to avoid damaging the transmission. The gear is only
engaged when the vehicle is stopped. If testing this, do so
carefully!
3- The Selector Lever Transmission Range Display - Y5- is
completely lit up and blinking. The selector lever position is
indicated/highlighted. Example: the transmission fluid tem‐
perature is too high. Reasons could include: towing a trailer

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with too large of a load, accessories installed on the front of

the vehicle, »lack of cooling air«.
4- The selector lever position engaged cannot be recognized.
The Selector Lever Transmission Range Display - Y5-
blinks. Differences in the driving and shifting can definitely
be felt. It is not possible to shift into reverse. There is a »se‐
rious malfunction«, a sub-transmission is switched off,
transmission repair is necessary.
2.3 Fault Finding, Special Information

⇒ “2.3.1 Transmission Range Display, No R ”, page 7
⇒ “2.3.2 Touch Function Malfunction, Not Changing Gears as
Usual”, page 7
⇒ “2.3.3 Drive Faulty - Insufficient Oil Suspected”, page 7
⇒ “2.3.4 No Faults are Stored”, page 7
⇒ “2.3.5 Faults are Stored”, page 8
⇒ “2.3.6 Malfunctions Outside Transmission ”, page 8
2.3.1 Transmission Range Display, No “R”

Simultaneous lighting of all segments on the transmission range
display indicates the transmission is in emergency mode. The
vehicle can no longer drive in reverse.
2.3.2 Touch Function Malfunction, Not

Changing Gears as Usual
Check the lock washers on the selector lever cable mounting
bracket at the top of the transmission. The washer -B- especially
must never be used twice.
The lock washer -B- can deteriorate if it loses its »residual stress«.
The -arrow- points to the selector lever cable adjustment screw.
2.3.3 »Drive« Faulty - Insufficient Oil Suspec‐

ted
First click here once. Refer to
⇒ “1.5 DSG® Transmission Fluid”, page 3 .
Only add fluid if it has definitely been seen that oil has leaked out.
Under any other circumstances it is just an »unnecessary ex‐
pense« that does not help.
2.3.4 No Faults are Stored

In this case, it is especially up to the technician to find the solution.
Experience shows that often a »fault« that is attributed to the
transmission was caused by other components or assemblies.
It can be the case that poor shifting behavior is a result of insuf‐
ficient engine air supply. Do not make such a mistake.
If such faults are to be eliminated, work can be performed sensibly
with the VWtester.
2. Troubleshooting 7
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2.3.5 Faults are Stored

Find out which faults have been stored. Volkswagen testers offer
Guided Fault Finding . Using Guided Fault Finding cor‐
rectly can determine the cause of many malfunctions.
2.3.6 Malfunctions »Outside Transmission«

If, for example, there is a malfunction in the transmission: “ABS
signal missing” is stored in the transmission and perhaps another
control module also says: “ABS signal missing”: Then do not con‐
tinue to suspect the transmission control module is »faulty«.
The entry simply means: the transmission (and possibly other
control modules) is waiting for a signal from the BUS but is not
receiving it. In this case, the ABS control module would have a
problem. The DSG Transmission Mechatronic - J743- must never
be removed here under any circumstances. In this example, the
fault points to problems with the ABS.

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3 Transmission Identification
⇒ “3.1 Transmission Code, Reading”, page 9
Example -arrow-:
GKF - Transmission Code

10.05.2 - 05/10/2002
14 - Plant Code
14 15 - Time
001 - Serial Number
On some transmissions, additional code letters are applied on top

of the transmission near the selector lever cable -arrows-.
The transmission code is also listed on the vehicle data label.
If the vehicle data label is not available, a different transmission
was accidentally installed or there is no definite way to identify the
installed transmission, read the transmission code letters directly
from the transmission.
Reading the code directly off the transmission. Refer to
⇒ “3.1 Transmission Code, Reading”, page 9 .
3.1 Transmission Code, Reading

The transmission code is on every transmission in at least two
different locations.
3. Transmission Identification 9
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One is on top of the transmission near the selector lever cable

-two arrows-.
If these cannot be read or are »on the head«, the transmission
code can also be read under the left subframe mount transmis‐
sion bracket.
To read the transmission code letters under the transmission

bracket directly from the transmission, the engine and transmis‐
sion must be supported. The left subframe mount transmission
bracket -A- must be removed. It is important to lower the engine/
transmission just enough until it is possible to slide the bracket
toward the rear. If lowered any farther, the pendulum support
could be damaged. After being assembled, the selector lever ca‐
ble must be adjusted. Refer to
⇒ “5.6 Selector Lever Cable, Adjusting”, page 80 .
Perform the Following:
– Remove the air filter housing.
♦ Vehicles with a gasoline engine. Refer to ⇒ Rep. Gr. 24 ; Air
Filter; Air Filter Housing, Removing and Installing .
♦ Vehicles with a diesel engine. Refer to ⇒ Rep. Gr. 23 ; Diesel
Direct Injection System; Air Filter Housing, Removing and In‐
stalling .
– Remove the battery and the battery tray -arrows-. Refer to ⇒

Electrical Equipment; Rep. Gr. 27 ; Battery; Battery, Remov‐
ing and Installing .
Mount the Engine Support Bridge - 10-222A- and support the en‐
gine with the transmission. Do not lift.

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– Remove the bolts -1 and 2- from the transmission bracket

-A-.
The bolts must be replaced.
– Then slightly lower the engine/transmission using the Engine
Support Bridge - 10-222A- spindles until the transmission
bracket can be removed.
In most cases two turns on the spindle are enough to remove the
bracket in direction of -arrow-.
After reading the transmission code, re-assemble in reverse order
of removal.
– Follow all the instructions.
– Replace all the bolts from the left subframe mount.
– Install all new bolts first by hand.
– Attach the transmission bracket -A- to the transmission using

the bolts -1 and 2-. Refer to
⇒ “6.3 Tightening Specifications”, page 100 .
– After installing the transmission bracket, always adjust the se‐
lector lever cable. Refer to
3. Transmission Identification 11
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4 Engine Codes - Engine Allocation

⇒ “4.1 Codes”, page 12
4.1 Codes
If original parts are needed for a repair, always pay attention to
the transmission codes.
DSG Transmission 02E
JBT, JPS, KDC, GPW, GYQ, HLH, HBP, HFQ, HLE, HBQ, HRW,
KNF, KPY, KVV, HQH, HQQ, HQN, HQF, HQL, HXS, HUS, HUT, HXW,
LRC HXU, JPL, KCW, JPJ, KCU, KMW, JPP, KCZ, KNC,
KMZ, KPQ, LQS, KMX, KPS, KQC, KPV, LQZ, LTL,
MKJ, MLW LQT, LTD, LQV, MMA, MSX,
LTE, MFL, MFM, MSY, NJL, NJM,
MSU, MSV, NJK, NLQ, NVW, PBG,
NLP, PBF, PPY PPZ, PQL
1.4L - 103 kW TSI 1.9L - 74 kW TDI 2.0L - 100 kW TDI 2.0L - 147 kW
1.4L - 125 kW TSI 1.9L - 77 kW TDI 2.0L - 103 kW TDI TFSI
2.0L - 125 kW TDI
installed in Golf Wagon from MY 2007, Golf Wagon from MY 2010, Jetta from MY 2005 and
Jetta from MY 2011
For the following data. Refer to the Parts Catalog.
♦ The individual gear ratios
♦ Transmission fluid
♦ Clutch allocation

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5 Capacity
Capacities DSG Transmission 02E
Refill Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03
Change Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03
Change after removing and installing the Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03
Mechatronic with the transmission installed
Grease Transmission fluid for DSG® transmission 02E. Refer to the
Parts Catalog .
5. Capacity 13
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6 Special Tools
Special tools and workshop equipment required
♦ Torque Wrench 2-10Nm - VAG1783-

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30 – Clutch
1 Overview - Dual Clutch
Dual Clutch General Information
The term »clutch« is not completely accurate on closer examina‐

tion. DSG® clutches always contain at least two »clutches« which
is why the term “dual clutch” is more appropriate. In this case, the
clutch has two clutch disc packs - that is, a wet clutch. The outer,
larger clutch plate pack is called “K 1” (clutch 1). The “K 1” shifts
reverse gear and »1st«, »3rd« and »5th« gears. The inner, small‐
er “K 2” (clutch 2) shifts the gears »2«, »4« and »6«.
Assembling the dual clutch requires special care, because all of
the components were balanced to each other at the manufacturer.
When positioning components during installation, do not rotate
out of their original position, otherwise imbalances will occur, cre‐
ating diminished shift comfort and life span.
Replacement clutches are supplied with the circlip already instal‐
led.
To avoid the risk of turning parts from one another in the first
place, it is shown here how the clutch is assembled in the trans‐
mission housing and installed. Follow the descriptions exactly.
Refer to ⇒ “2 Dual Clutch, Removing and Installing”, page 18 .
Replacement Part Package
1. Overview - Dual Clutch 15

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1 - Dual Clutch with Circlip
Caution
The
♦ drive plate (upper
section of the dual clutch)
of a new clutch is not se‐
cured with the circlip, it
only sits »taut« in the
clutch.
The
♦ drive plate must re‐
main engaged between
the teeth of the outer
clutch plate carrier.
If♦the drive plate is loos‐
ened, the plates in the
dual clutch can slip out of
place and it cannot be ad‐
justed correctly during in‐
stallation under the cir‐
cumstances.
2 - Circlip
❑ Quantity: 10, with vari‐
ous thicknesses for ad‐
justment
❑ When installing the dual
clutch, the thickness of
the circlip must be de‐
termined. Refer to
⇒ page 28
3 - Clutch End Cover
4 - Clutch End Cover Circlip
Individual Components of Disassembled Dual Clutch
Caution
16 Rep. Gr.30 - Clutch

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1 - DSG® Clutch/Clutch Hous‐

ing
❑ Outer clutch plate carri‐
er
2 - Seal
❑ Quantity: 4
3 - Inner Clutch Plate Carrier
❑ Do not remove
Caution
Do not lift or remove the
inner clutch plate carrier
under any circumstan‐
ces. The clutch plates
could rotate themselves.
4 - Outer Clutch Plate

❑ Quantity: 4
5 - Inner Clutch Plate
❑ Quantity: 4
6 - Thrust Washer
7 - Circlip
❑ If the circlip was re‐
moved in order to rein‐
sert the plates, it should
be replaced with a new
ring of the same thick‐
ness.
8 - Circlip
❑ After installing a new du‐
al clutch, redetermine
the thickness. Refer to
⇒ page 28 .
9 - Drive Plate
10 - Circlip
❑ Replace after removing
❑ Do not install any wavy circlips
1. Overview - Dual Clutch 17

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2 Dual Clutch, Removing and Installing

⇒ “2.1 Remove Clutch End Cover”, page 18
⇒ “2.2 Clutch End Cover, Installing”, page 20
⇒ “2.3 Dual Clutch, Removing”, page 24
⇒ “2.4 Dual Clutch, Installing and Adjusting”, page 25
Before the dual clutch can be removed, remove the clutch end
cover from the dual clutch. Refer to
⇒ “2.1 Remove Clutch End Cover”, page 18 .
2.1 Remove Clutch End Cover

Brief Description
The clutch cover closes the transmission toward the outside. A
circlip holds the clutch end cover in place. Remove the circlip and
pry out the clutch end cover. Always replace the clutch end cover
and the locking ring. Never use a hammer to install the clutch
cover and never lubricate the center seal or touch it. If this should
occur, the clutch cover will certainly leak!
The transmission must be removed in order to work on the cover.
– Remove the transmission. Refer to
⇒ “6 Transmission, Removing and Installing, Jetta from MY
2005 , Golf Wagon from MY 2007 and Golf Wagon from MY
2010”, page 88 or
⇒ “7 Transmission, Removing and Installing, Jetta from MY
2011”, page 102 .
– Secure the transmission on the assembly stand. Refer to
⇒ “8 Transmission, Transporting and Securing to Assembly
Stand”, page 131 .
– Place a Drip Tray under the transmission.
– Drain the fluid.

Then the second plug was discontinued so that draining oil and
adjusting the oil level can both be done using plug -A-.
A plastic overflow tube is located in this hole (with 8 mm hex
– Remove this overflow pipe and drain the remaining transmis‐
sion fluid.
Note
Approximately 5 liters (5.28 qts) of transmission fluid will flow out.

Leave the Drip Tray under the transmission.
– Install the overflow pipe and tighten it to 3 Nm.

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– Install the drain plug with a new seal -arrow-.

Tightening Specification: 45 Nm
– Remove the filter if necessary.

There are Often Uncertainties as to Whether the Filter Must Be
Replaced or Not.
The information on changing the fluid filter can help when making
this decision. Refer to
⇒ “1.5.2 Transmission Fluid Filter, When To Change ”, page 4 .
– Insert the new filter with the seat facing downward and tighten
the housing to 20 Nm.
– After repairing, the filter does not have to be changed again
when the filling fluid.
Removing the Clutch End Cover
2. Dual Clutch, Removing and Installing 19

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– Pry out the circlip -2- for the clutch end cover with a screwdriver
-1- in direction of -arrow- and remove.
– Remove the clutch end cover -2- with a screwdriver -1- (or a
pry bar) through the opening for the starter in the direction of
-arrow- and then remove the clutch end cover.
Note
♦ The clutch end cover that was removed cannot be installed

again.
♦ Only install a »new« clutch end cover. Refer to
⇒ “2.2 Clutch End Cover, Installing”, page 20 .
2.2 Clutch End Cover, Installing

⇒ “2.2.1 Clutch End Covers Delivered without Bushings, Instal‐
ling”, page 21
⇒ “2.2.2 Clutch End Covers Delivered with Bushings, Installing”,
page 23
There Are Two Types of Clutch End Covers.

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♦ Clutch end covers that are delivered without bushings. Refer

to
⇒ “2.2.1 Clutch End Covers Delivered without Bushings, In‐
stalling”, page 21 .
♦ Clutch end covers that are delivered with a white bushing. Re‐
fer to
⇒ “2.2.2 Clutch End Covers Delivered with Bushings, Instal‐
ling”, page 23 .
2.2.1 Clutch End Covers Delivered without

Bushings, Installing
♦ Clutch Cover Plate Guide Sleeve - T10302-
Always replace the clutch end cover and the locking ring. Never
use a hammer to install the clutch cover and never lubricate the
center seal or touch it.
Caution
Do not touch the hole in the center in a new clutch end cover.
The clutch end cover must not be touched inside the hole, oiled
or come into contact with any other substances in that area.
Leaks will develop.
– Only hold the clutch end cover as illustrated.
Caution
Clean the assembly sleeve before use and do not use scratch‐
ed assembly sleeves.
The new clutch cover must not have any oil in the around the
center seal and it must be dry.
– Clean end of clutch shaft if necessary.
Do not apply adhesive to inside of the cover.
– If this is done, carefully remove the adhesive!
Only coat outer edge of seal with DSG® transmission fluid.
– Place the sleeve on a level surface
The center seal on new clutch end cover must now be »pre-
formed«:

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– Guide the clutch end cover horizontally and evenly over the
whole sleeve. This brings the sealing lip into its installation
position.
– Remove the sleeve upward out of the clutch end cover and
place it on the end of the clutch shaft.
– Guide the clutch end cover horizontally over the sleeve and
press it evenly onto its seat.
Caution
Handle with care. Any type of impact on the clutch end cover
will cause leaks.
The clutch end cover can be carefully lifted in its seat using a
screwdriver -arrow- until a »new« locking clip can be installed.
– Install the new circlip.
– Remove the Clutch Cover Plate Guide Sleeve - T10302- .

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2.2.2 Clutch End Covers Delivered with Bush‐

ings, Installing
Always replace the clutch end cover and the locking ring. Never
use a hammer to install the clutch cover and never lubricate the
center seal or touch it.
Caution
Do not touch the hole in the center in a new clutch end cover.
The clutch end cover must not be touched inside the hole, oiled
or come into contact with any other substances in that area.
Leaks will develop.
Do Not Remove the Bushing!

The new clutch cover must not have any oil in the around the
center seal and it must be dry.
– Clean the end of the clutch shaft if necessary.
Do not apply any stickers to inside of the clutch end cover.
– If this is done, carefully remove the adhesive!
Only coat outer edge of seal with DSG® transmission fluid.
– Install the clutch end cover with bushing.
Caution
Handle with care. Any type of impact on the clutch end cover
will cause leaks.
The clutch end cover can be carefully lifted in its seat using a
screwdriver -arrow- until a »new« locking clip can be installed.
– Install the new circlip.

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– Only remove the bushing once the circlip is installed.
2.3 Dual Clutch, Removing

To remove and install the dual clutch, the transmission must be
secured in a vertical position on the assembly stand.
– Remove the clutch end cover. Refer to
⇒ “2.1 Remove Clutch End Cover”, page 18 .
– Pry out the drive plate circlip -2- with a screwdriver -1- in di‐
rection of -arrow-.
– Remove the drive plate in direction of -arrows-.

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– Remove the circlip -arrow-.

This circlip must be remeasured and replaced later when instal‐
ling.
Caution
Carefully remove the dual clutch. Make sure that no other parts
of the clutch fall out. Never turn over the clutch for this reason!
– Carefully remove the dual clutch from the transmission.
– Remove the pump shaft -A-.

– The pump shaft will be inserted first after the installation of the
new clutch. Set the shaft down until then.
2.4 Dual Clutch, Installing and Adjusting

♦ Clutch Retaining Bar - T10303-
Caution
♦ The drive plate of a new clutch is not secured with a circlip,

it only sits “taut” in the clutch.
♦ Thus, press the drive plate into the outer clutch plate car‐
rier with both thumbs during the following steps.
♦ The drive plate must remain engaged between the teeth
of the outer clutch plate carrier.
♦ If the drive plate is loosened, the clutch plates in the dual
clutch can slip out of place. The dual clutch may not be
correctly set during installation under certain circumstan‐
ces.

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• Transmission must be turned »vertically in assembly bracket«.

This is the only position in which the clutch axial play can later
be adjusted without malfunctions.
• Make sure the transmission is secure inside the Holding Fix‐
ture - VW313- or Engine And Transmission Holder -
VAS6095- . Refer to
Stand”, page 131 . Do not turn it.
• The large lamella carrier is inserted in all clutch discs in the
clutch. The large lamella carrier must not slipped out of the
lowest clutch disc.
• Oil pump shaft is removed.
• Do not install any wavy circlips
– Take the dual clutch out of the packaging by pressing the drive
plate into the outer clutch plate carrier with both thumbs.
– Next, secure the drive plate in the outer clutch plate carrier
with the “old” circlip -A- from the removed clutch.
• Do not use the new circlip that was delivered with the package.
• The circlip must be installed so that the tab of the drive plate
-arrow- and the color-marked teeth of the outer clutch plate
carrier are positioned between both ends of the circlip.
– Check the bottom of the dual clutch to see if the four hub gas‐
kets are seated correctly and engage them in one another if
necessary.
• The ends of the rings should not stand over one another.
– Turn the rings one time. They must move freely and must not
stick.

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Important! Installation Position of the Drive Plate

– Verify that the protruding tab -arrow- of the drive plate is posi‐
tioned between the color-marked teeth of the outer clutch plate
carrier.
If no marking is available:
– Mark the location of the tab to the outer clutch plate carrier
circumference with a waterproof marker as shown.
• When installing, the drive plate tab must be placed back on
this marked location.
– Insert the Clutch Retaining Bar - T10303- in the position on the

clutch end cover as shown.
– Set the dual clutch using rotating and lifting movements into
the clutch housing, but do not let it fall in. Press the drive plate
into the outer clutch pack carrier with both thumbs in direction
of -arrows- to install.
Do not install on clutch. The clutch is inserted with the cover as it
was in the packaging.
• A second technician should hold the Clutch Retaining Bar -

T10303- .
Note
♦ The retaining pin remains there until clutch end cover is in‐
stalled.
♦ The dual clutch must not be turned any more now, otherwise
the Clutch Retaining Bar - T10303- could be twisted in its po‐
sition.

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– Remove and dispose of the old locking ring -2- using a screw‐
driver -1- in direction of -arrow-.
Caution
Do not remove or lift the inner clutch plate carrier, under any
circumstances. The clutch plates could rotate themselves.
– Remove the drive plate from the installed clutch in direction of

-arrows-, if necessary, use a screwdriver to carefully pry it out
of the teeth of the outer clutch plate carrier.
– Move the drive plate to the side.
Identifying the Circlip for the Dual Clutch.

– Select the 2 mm thick ring from the circlips delivered and install
it -arrow-.
Note
For the initial measurement, temporarily insert 2 mm thick circlip.

After the measurement has been determined, replace it with the
final circlip.
First Measurement
• The Clutch Retaining Bar - T10303- remains installed.
– Install the Dial Gauge Holder - VW387- on the transmission
flange.

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– Place the -dial gauge test probe- on the input shaft.

– Set the -dial gauge- to “0” with 2 mm pretension.
– Raise the dual clutch up as far as the stop and note the meas‐
urement result.
Second Measurement
• The Clutch Retaining Bar - T10303- remains installed.
– Place the dial gauge test probe on the

-inner clutch plate carrier hub-.
Note
Do not place the dial gauge test probe on the circlip.
– Set the -dial gauge- to “0” again with 2 mm pretension.

– Raise the dual clutch up as far as the stop again and note this
measurement as well
Now the Calculation Will Be Made to Determine Which of the Re‐
maining Nine Circlips Will Be Finally Installed:
– Use this formula:
2nd measurment value - 1st measurment value + 1.85 mm =
circlip thickness
– Note the result.
The remaining nine circlips are staggered in 0.1 mm increments.
– Measure all the circlips and determine the one that is the clos‐
est match to the result.
Determined Measurement for New Circlip
the New Circlip
2.27 mm 2.3 mm
2.24 mm 2.2 mm
Note
If the measurement determined for the new circlip is 2 mm, the

circlip that was inserted temporarily remains installed.

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– Remove the 2 mm circlip and replace it with the circlip that was
measured.
– Dispose of all other remaining circlips and the 2 millimeter thick
circlip.
Note
Circlips must only be installed one time.
– Insert the pump shaft by lifting the pump shaft and turning it
slightly -arrow- so that it slides all the way into the splines.
– Insert the drive plate into the dual clutch.

• The protruding tab on the drive plate -arrow- must be installed
between the marked teeth or the marking applied to the outer
clutch plate carrier.
– Install the »new« drive plate circlip.

• The circlip must be installed so that the tab of the drive plate
and the color-marked teeth of the outer clutch pack carrier are
positioned between both ends of the circlip.
• The circlip must be completely engaged.
– Check the exact installation position of the circlip and that the
circlip is engaged using a screwdriver.

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– Now remove the Clutch Retaining Bar - T10303- between the

dual clutch and the housing.
– Install the clutch end cover. Refer to
⇒ “2.2 Clutch End Cover, Installing”, page 20 .
When the Installation Is Completed, the Clutch Is Adjusted Cor‐
rectly.
– Install the transmission. Refer to
⇒ “6.2 Transmission, Installing”, page 97 or
⇒ “7.4 Transmission, Installing, Jetta MY 11, 2.0L 147 kW
Gasoline Engine”, page 127 .
– Fill with transmission fluid. Refer to
⇒ “9.3 Fluid, Draining and Filling”, page 136 .
– After installing the transmission, perform the basic set-
ting using the Guided Functions using the Vehicle Diag‐
nostic Tester .

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3 Special Tools
♦ Clutch Cover Plate Guide Sleeve - T10302-
♦ Clutch Retaining Bar - T10303-

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34 – Controls, Housing
1 Electrical and Electronic Compo‐
nents, Component Locations in
DSG® Transmission
The electric/electronic components are located inside the trans‐
mission.
The Selector Lever Sensor System Control Module - J587- and
the Shift Lock Solenoid - N110- are located on the selector lever.
1 - DSG Transmission Mecha‐

tronic - J743-
❑ Behind the »large« met‐
al cover
❑ Removing and installing
with transmission instal‐
led. Refer to
⇒ “1.1 DSG Transmis‐
sion Mechatronic J743 ,
Removing and Instal‐
ling, Transmission In‐
stalled”, page 34 .
❑ Removing and installing
with transmission re‐
moved. Refer to
⇒ “1.2 DSG transmis‐
ling, Transmission Re‐
moved”, page 45 .
2 - Transmission Input Speed
Sensor - G182- and Clutch Oil
Temperature Sensor - G509-
❑ The DSG Transmission
Mechatronic - J743-
must be removed first
before the sensor can
be removed. Refer to
⇒ “1.1 DSG Transmis‐
ling, Transmission In‐
stalled”, page 34 .
3 - Selector Lever - E313-
❑ For more information on
the selector lever. Refer
to
⇒ “5 Selector Mecha‐
nism”, page 62
1. Electrical and Electronic Components, Component Locations in DSG® Transmission 33

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1.1 DSG Transmission Mechatronic -

J743- , Removing and Installing, Trans‐
mission Installed
⇒ “1.1.1 Mechatronic, Removing, Transmission Installed”,
page 34
⇒ “1.1.2 Mechatronic, Installing, Transmission Installed”,
page 39
⇒ “1.2 DSG transmission Mechatronic J743 , Removing and In‐
stalling, Transmission Removed”, page 45 .
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Used Oil Collection and Extraction Unit - SMN372500-
♦ Oil Filler - VAS6262A-
♦ Speed Sender Release Tool - T10465-
1.1.1 Mechatronic, Removing, Transmission

Installed
transmission.
Any dirt that enters can cause transmission failure, especially if
the DSG Transmission Mechatronic - J743- and/or the oil pump
are »exposed«.
In regard to »contaminated oil«, also observe information on
changing the oil filter. Refer to
The Mechatronic can get stuck on the alignment pins when the
transmission is very warm. Let the transmission cool down.
– Move the selector lever into “P”.
– Disconnect the battery ground cable. Refer to ⇒ Electrical
Equipment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and
Connecting .
– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.
Gr. 50 ; Noise Insulation .
If present:
– Remove the connecting hose between the charge air cooler
and the charge air pipe. Refer to ⇒ Rep. Gr. 21 ; Charge Air
System .
Only on the 1.4L Engine
– Move the lock carrier into the service position. Refer to ⇒ Body
Exterior; Rep. Gr. 50 ; Lock Carrier; Service Position .
Continuation for All Vehicles
Note
It is possible that parts, which have nothing to do with the Me‐

chatronic unit, will have to be removed. It depends on the vehicle
equipment. Make sure there is enough room around the Mecha‐
tronic unit.
34 Rep. Gr.34 - Controls, Housing

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♦ Depending on the vehicle, the parts could be:

♦ Fan mount -arrow-
♦ Additional lines for the A/C systems
♦ Charge or cold air pipes
Caution
There is a risk of damaging the DSG Transmission Mecha‐

tronic - J743- with static electricity.
♦ Do not touch contacts in DSG Transmission Mechatronic
- J743- connector with hands.
– To discharge any static electricity, touch the vehicle ground

with hand (without wearing a glove). Refer to
⇒ “1.7 Electrical Components”, page 5 .
– Turn the Mechatronic connector lock -1- »counter-clockwise«

to release and disconnect the connector.
Note
The connector is located on the transmission near the starter

-A-.
– Remove the wires and bracket from the front of the transmis‐
sion cover -arrows- (two M6 nuts).
Tightening Specification for the nuts: 10 Nm
– Position lines in cover area upward and tie up.
– Place the Used Oil Collection and Extraction Unit -
SMN372500- under the transmission near the »large« cover.
Caution
Fluid will leak out of the cover when the bolts are removed. Risk
of injury due to hot transmission fluid.
– Loosen bolts on the transmission cover -arrows- diagonally

first and then remove them. Hold the cover in place at the same
time.
– Drain the gear oil and remove the cover and seal.
Approximately three liters (3.1 quarts) of transmission fluid will
drain out.
Note
Always replace the »small« oil pump cover, the seal and the bolts
on the transmission cover.

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– Remove the oil pump cover -A-.
– Remove the bolts -2 and 3- from the transmission pendulum

support. Refer to ⇒ Rep. Gr. 10 .
The transmission can now be »pressed down« slightly to remove
the Mechatronic.
Before handling the Mechatronic, touch a grounded object again.

Refer to ⇒ “1.7 Electrical Components”, page 5 .
– Release the connector -1- of the Transmission Input Speed

Sensor - G182- and Clutch Oil Temperature Sensor - G509-
using the Speed Sensor Release Tool - T10465- .

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Note
♦ If the Speed Sender Release Tool - T10465- is not available,

the connector can be removed by carefully using two screw‐
drivers as follows:
♦ Press only on the release with the screwdriver -1-. Do not use
a screwdriver as a lever.
♦ Loosen the connector with the screwdriver -2-.
♦ Be very careful. The connector locking mechanisms can
break. Replace the sensor if this happens.
Do Not Pull On the Wire

– Disconnect the connector.
– First remove line from the lower clamp -arrow I-.

– Then remove from the second clamp -arrow II- and move it to
the side. Do not kink line.
– Loosen and remove the bolts -1 through 10- in the specified

sequence.

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– Carefully pull the Mechatronic out of the transmission housing

until the sensor arm -B- on rear side is no longer located in
transmission housing.
When handling the Mechatronic, be particularly aware of the
»long« sensor arm -B-.
– Carefully move the DSG Transmission Mechatronic - J743-
downward.
Store the Mechatronic Properly
Caution
Never lift the Mechatronic by the »sensor arm« and never let
it rest on the arm.

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Replace the Mechatronic if the »arm« Gets Damaged.
1.1.2 Mechatronic, Installing, Transmission

Installed

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Note
♦ The DSG Transmission Mechatronic - J743- and the trans‐

mission must be the same temperature. Otherwise the align‐
ment pins will not »clamp« during installation.
♦ Make sure the Transmission Input Speed Sensor - G182- and
the Clutch Oil Temperature Sensor - G509- are installed be‐
fore installing the Mechatronic.
♦ Do not pinch the line.
– Carefully mount the Mechatronic onto the alignment pins

-arrow-. The goal is for the »sensor arm« to be in its
-installation position-.

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– Hold the Mechatronic facing up. The sensor arm must not
touch the sensor wheel. -Detail-
– Make sure the Mechatronic unit is installed correctly.
– Install the new bolts -1 through 10- hand-tight.
– Tighten the bolts to 5 Nm + 90° (1/4 turn) in the specified se‐
quence.
– Engage the wire -A- first into the upper and then the lower tab
-arrows-.
– Connect the connector.

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– Replace both -O-rings- if installing the »old« Mechatronic.

– Coat the O-rings with DSG® transmission fluid.
A »new« Mechatronic already has »new« O-rings.
– Replace the transmission cover gasket.
– Clean the sealing surface on the transmission.
– Make sure the seal fits correctly.
– Place the transmission cover -A- over the Mechatronic. Be

careful not to pinch any wires when doing this.
– Install new bolts -arrows- and tighten to 10 Nm diagonally and
in several steps.
– Attach the cable bracket to the transmission cover and tighten

the nuts -arrows- to 10 Nm.
– Set the new oil pump cover -A- in place and tighten the bolts
-arrows- in a diagonal sequence to 8 Nm in stages.

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Connect the connector -A- from the DSG Transmission Mecha‐

tronic - J743- as follows.
– The arrow -D- on the Mechatronic -B- must line up with the
connector -A- as well as with the tab -C-.
– Connect the connector -A- carefully all the way and then turn
the lock »clockwise« in the direction of -arrow-.
– Install the hose between the charge air cooler and the charge
air pipe, if was removed earlier. Refer to ⇒ Rep. Gr. 21 ;
Charge Air System .
– Attach the pendulum support to the transmission using new
bolts. Refer to ⇒ Rep. Gr. 10 .
– Reinstall any removed vehicle parts.
– Connect the battery and follow the steps after connecting the
battery. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery;
Battery, Disconnecting and Connecting .
– Do not start the engine.

– Change the filter if the fluid is dirty.
– Replace the DSG® fluid and filter. Refer to
page 132 .
SMN372500- under the transmission near the drain plug.
– Remove the drain plug near the pendulum support -arrow-.

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– Measure the length of the vent pipe, dimension -a- before in‐
stalling Oil Filler - VAS6262A- on the oil bottle and shorten the
pipe if necessary. Refer to ⇒ page 134 .
Dimension -a- = 210 mm
Note
Dimension -a- is measured starting from the shaft (the green sur‐
face) on the Oil Filler - VAS6262A- .
– Install the Oil Filler - VAS6262A- into the check hole hand-
tight.
– Shake the bottles before opening.

– Attach the Oil Filler - VAS6262A- to the oil bottle. Be sure to
read the instructions. Refer to ⇒ page 133 .
– Fill three (3.1 quarts) liters of fluid.
– To change containers, close the shut-off valve or hold the Oil
Filler - VAS6262A- higher than the transmission.
Start the engine and check the fluid level. The Oil Filler -
VAS6262A- remains installed.
– Check the fluid level and fill if necessary. Refer to
– Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr.
50 ; Noise Insulation .
– Connect the Vehicle Diagnostic Tester .
– Perform a basic setting on the DSG Transmission Mechatronic

- J743- .

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1.2 DSG transmission Mechatronic - J743- ,

Removing and Installing, Transmission
Removed
⇒ “1.2.1 Mechatronic, Removing, Transmission Removed”, page
45
⇒ “1.2.2 Mechatronic, Installing, Transmission Removed”,
page 50
♦ Speed Sender Release Tool - T10465-
transmission. Any dirt that enters can cause transmission failure,
especially if the DSG Transmission Mechatronic - J743- and/or
the oil pump are »exposed«.
1.2.1 Mechatronic, Removing, Transmission

Removed
SMN372500- or Drip Tray under the transmission.
– Remove the bolt -A- near the pendulum support.
– Remove the overflow pipe.
– Tighten the overflow pipe to 3 Nm.

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– Remove the filter if necessary.

There Are Often Uncertainties As to Whether the Filter Must Be
Replaced or Not.
The information on changing the fluid filter can help when making
this decision. Refer to
– Insert the new filter with the seat facing downward and tighten
the housing to 20 Nm.
Note
After repairing, the filter does not have to be changed again when
filling the fluid.
– Remove the transmission cover and the transmission fluid

pump cover.
Note
Always replace the transmission fluid pump cover, the bolts for
the transmission fluid pump cover as well as the gasket and the
transmission cover bolts.


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– Release the connector -1- of the Transmission Input Speed

Sensor - G182- and Clutch Oil Temperature Sensor - G509-
using the Speed Sensor Release Tool - T10465- .
Note
♦ If the Speed Sender Release Tool - T10465- is not available,

the connector can be removed by carefully using two screw‐
drivers as follows:
♦ Press only on the release with the screwdriver -1-. Do not use
a screwdriver as a lever.
♦ Loosen the connector with the screwdriver -2-.
♦ Be very careful. The connector locking mechanisms can
break. Replace the sensor if this happens.

– Disconnect the connector.
– First remove line from lower clamp -arrow I-.

– Then remove it from the upper clip -arrow II- and move it to the
side. Do not kink line.
– Remove the bolts -1 through 10- is a diagonal sequence. Start

with the bolt -1-.

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Replace all 10 -bolts-.

– Remove the DSG Transmission Mechatronic - J743- .
When handling the Mechatronic, be particularly aware of the
»long« sensor arm.
Caution
it rest on the arm.

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Store the Mechatronic Properly

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1.2.2 Mechatronic, Installing, Transmission

Removed
Caution
it rest on the arm.
– Make sure the Transmission Input Speed Sensor - G182- and

the Clutch Oil Temperature Sensor - G509- are installed.

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– Replace both -O-rings- for the Mechatronic connection if an

»old« Mechatronic is being re-installed.
A »new« Mechatronic already has »new« rings.
– Coat the O-rings with DSG® transmission fluid.
– Carefully place the Mechatronic on the alignment pin -arrow-.

The goal is for the »sensor arm« to be in its
-installation position-.

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– The sensor arm must not touch the sensor wheel. -Detail-
– Do not pinch the line.
– Make sure the Mechatronic unit is installed correctly.
All of the bolts -1 through 10- must be replaced.
– Install the bolts -1 through 10- »by hand«.

– Tighten all the bolts -1 through 10- in a diagonal sequence to
5 Nm. Then tighten an addition 90° in the same order. Start
with the bolt -1-.

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– Install the Transmission Input Speed Sensor - G182- and

Clutch Oil Temperature Sensor - G509- wire in the upper
clamp -arrow II- first. Then install them in the lower clip
-arrow I-.
– Press the connector onto the Mechatronic.
Always replace the »small« oil pump cover and the bolts for the
transmission cover.
Replace the transmission cover -gasket-.
– Fasten bolts -arrows- for the transmission cover -A- »in a di‐
agonal sequence« to 10 Nm.
After Installing Transmission
– Fill the fluid without replacing filter. Refer to
page 132 .
– Connect the Vehicle Diagnostic Tester .
– Perform a basic setting on the DSG Transmission Mechatronic
- J743- .
1.3 Transmission Input Speed Sensor -

G182- and Clutch Oil Temperature Sen‐
sor - G509- , Removing and Installing
Both sensors are a single component and can only be replaced
together. They are »coated with oil« in transmission near the mul‐
ti-plate clutch. Before removing, the DSG Transmission Mecha‐
tronic - J743- must be removed.

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Often, the sensor wire is pulled. It will get damaged. If the wire
was pulled, the sensor must be replaced.
Removing
– Remove the DSG Transmission Mechatronic - J743- . Refer
to
⇒ “1.1 DSG Transmission Mechatronic J743 , Removing and
Installing, Transmission Installed”, page 34 .
– Remove the bolt and carefully pry out the sensor with screw‐
driver and/or pliers.
Installing
Install an »old« sensor only if:
• The sensor is working correctly.
• The wire was not pulled out during removal.
If this is not the case, a »new« sensor should be installed.
– Coat the sensor with DSG® transmission fluid and then install
it.
– Tighten the bolt to 10 Nm.
– Install the DSG Transmission Mechatronic - J743- . Refer to
⇒ “1.1 DSG Transmission Mechatronic J743 , Removing and
Installing, Transmission Installed”, page 34 .
Do not pinch line when installing the Mechatronic!

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2 Transmission Fluid Cooler, Remov‐

ing and Installing
Removing
♦ Hose Clamps - Up To 25mm - 3094-
♦ Engine Bung Set - VAS6122-
– Remove the battery and the battery tray. Refer to ⇒ Electrical
Equipment; Rep. Gr. 27 ; Battery; Battery, Removing and In‐
stalling .
– Place a lint-free cloth on to transmission fluid cooler and trans‐
mission to absorb escaping coolant.
Note
♦ The cooling system is under pressure when the engine is

warm.
♦ Cover the coolant reservoir cap with a cloth and open it care‐
fully before removing the coolant hoses.
– Disconnect the coolant hoses with Hose Clamps - Up To

25mm - 3094- and remove them from the transmission fluid
cooler.
– Seal off the transmission fluid cooler connections with suitable
sealing plugs taken from the Engine Bung Set - VAS6122- .
– Remove the bolts -A- and the transmission fluid cooler -B-.
Caution
Coolant must not drip into transmission!
Installing
2. Transmission Fluid Cooler, Removing and Installing 55

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– Replace the O-rings -C- from the transmission fluid cooler

-B-.
– Mount the transmission fluid cooler -B-, at the same time, pay
attention to the O-rings -C-.
– Tighten the new bolts -A- to 20 Nm + 90° (1/4 turn).
– Attach the coolant hoses to the transmission fluid cooler and

remove the Hose Clamps - Up To 25mm - 3094- .
– Install the battery and the battery tray. Refer to ⇒ Electrical
stalling .
– Check the coolant level and fill if necessary. Refer to ⇒ Rep.
Gr. 19 .
– After repairing, check the transmission fluid level and fill. Refer
to ⇒ “9.2 Fluid Level, Checking and Filling”, page 133 .
Caution
Do not start engine during coolant level test if the transmission

fluid has not been filled yet.

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3 Oil Pump, Removing and Installing

♦ Wrench - Pump/Injector Long Reach - T10054- .
Brief Description
The oil pump can be replaced without removing transmission. The
vehicle must be raised and any covers installed on bottom of front
end must be removed. The control arm to suspension strut con‐
nection does not need to be separated. The drive axle also does
not have to be removed. “Perform basic calibration” is not needed.
Only the DSG® transmission fluid and pump cover have to be
replaced.
Removing
– Remove the lower section of the left wheel housing liner. Refer
to ⇒ Body Exterior; Rep. Gr. 66 ; Wheel Housing Liner; Over‐
view - Front Wheel Housing Liner .
SMN372500- under the transmission.
– Remove the bolt -A- near the pendulum support.
– Remove the overflow pipe.
– Tighten the overflow pipe to 3 Nm.
– Replace the bolt seal -arrow-.

– The Used Oil Collection and Extraction Unit - SMN372500-
remains under the transmission.
3. Oil Pump, Removing and Installing 57

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– Remove the bolts -arrows- and the oil pump cover -A-.
There is Still Oil in Oil Pump Cover
– Remove the bolts -arrows- and the pump -1- from the align‐
ment pins and pull the input shaft from the pump.
Remove the top bolt with the Wrench - Pump/Injector Long Reach
- T10054- .
Installing
– Install the input shaft -A- all the way into the transmission. Turn
the input shaft while doing this.
– Always use a new metal seal -B-.
• The two alignment pins -C- must be inside the transmission
housing.
– When positioning the oil pump, pay attention to driveshaft
splines and correct seating on the alignment pins.
Different Oil Pump Bolts -1-

All four bolts -arrows- with flat heads
Tightening Specification
♦ 5 Nm + 90° (1/4 turn)

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3 bolts with flat head, top bolt -arrow- with countersunk head
Tightening Specification
♦ Countersunk bolt: tighten with the Wrench - Pump/Injector
Long Reach - T10054- 8 Nm without additional turn
♦ Flat head bolts: 8 Nm +90° (1/4 turn)
– Set the new oil pump cover -A- in place and tighten new bolts
-arrows- in diagonal sequence and in several steps to 8 Nm.
Transmission does not have oil. »New« oil must now be added
and adjust to the correct oil level. Refer to
page 132 .
– Install the left wheel housing liner. Refer to ⇒ Body Exterior;
Rep. Gr. 66 ; Wheel Housing Liner; Overview - Front Wheel
Housing Liner .
3. Oil Pump, Removing and Installing 59

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4 Selector Shaft Lever Gasket, Replac‐

ing
♦ Press Piece - Shift Rod/Alternator - VW423-
♦ Puller - Crankshaft/Power Steering Seal - T20143-
– Remove the selector lever cable from the transmission. Refer
to
⇒ “5.2 Selector Lever Cable, Removing and Installing, through
02/2009”, page 64 .
– Carefully pry the lever -A- off the selector shaft.
– Pry out the seal in the direction of -arrow-.
– Fill the space between the sealing/dust lip -arrow- halfway with
Sealing Grease - G 052 128 A1- .
– Lightly lubricate the outer edge of the gasket.

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– Install the new gasket all the way. Do not tilt the gasket when
installing it.
• The closed side of the gasket -arrow- points to the Press Piece
- Shift Rod/Alternator - VW423- .
– Install the lever and tighten the nut to 20 Nm.
The Selector Shaft Lever Fits on the Splines in One Position Only.
– Attach the selector lever cable to the transmission and adjust.
Refer to ⇒ “5.6 Selector Lever Cable, Adjusting”, page 80 .
4. Selector Shaft Lever Gasket, Replacing 61

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5 Selector Mechanism
⇒ “5.1 Overview - Selector Mechanism, Vehicles through
02/2009”, page 62
⇒ “5.2 Selector Lever Cable, Removing and Installing, through
02/2009”, page 64
⇒ “5.3 Overview - Selector Mechanism, Vehicles from 03/2009”,
page 72
⇒ “5.4 Selector Mechanism, Removing and Installing, Vehicles
from 03/2009”, page 73
⇒ “5.5 Selector Lever Cable, Checking”, page 80
⇒ “5.6 Selector Lever Cable, Adjusting”, page 80
⇒ “5.7 Selector Lever, Emergency Release”, page 82
⇒ “5.8 Selector Lever Handle, Removing and Installing”,
page 82
⇒ “5.9 Button in Handle, Moving into Installation Position”,
page 85
⇒ “5.10 Selector Mechanism, Checking”, page 86
WARNING
Move the selector lever into “P” and set the parking brake be‐
fore working with the engine running.
5.1 Overview - Selector Mechanism, Vehicles through 02/2009

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1 - Shift Cover with Handle

❑ Do not remove the han‐
dle unnecessarily. Only
the cover must be un‐
clipped for the emergen‐
cy release. Refer to
⇒ “5.7 Selector Lever,
Emergency Release”,
page 82 .
❑ Pull the button past its
pressure point before
removing the handle.
Secure the button with a
cable tie or some suita‐
ble wire. This prevents
the locking button from
being pushed back into
knob accidentally.
2 - Selector Lever and Selector
Mechanism
❑ With Shift Lock Solenoid
- N110-
❑ Emergency release.
Refer to
page 82 .
❑ Short description for re‐
moval and installation:
– Remove the center con‐
sole.
– Remove the selector

lever cable from the
transmission. Refer to
⇒ “5.2 Selector Lever
Cable, Removing and
Installing, through
02/2009”, page 64 .
– If necessary, disconnect or remove sections of the exhaust system. Refer to ⇒ Rep. Gr. 26 .
– Remove the heat shield under the selector mechanism.
– Adjust the selector lever cable after installing. Refer to

3 - Bolt with Spring

❑ 3 Nm
4 - Pin
❑ Removing. Refer to
⇒ “5.2 Selector Lever Cable, Removing and Installing, through 02/2009”, page 64 .
❑ Do not lubricate
5 - Locking Plate
❑ Always replace after removing
6 - Nut
❑ 9 Nm
❑ Quantity: 4
7 - Gearshift Housing
❑ With seal
5. Selector Mechanism 63
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8 - Adjusting Bolt
❑ 13 Nm
9 - Lock Washer
10 - Lock Washer
11 - Selector Lever Cable
❑ Do not grease the selector lever cable.
❑ Removing and installing. Refer to
⇒ “5.2 Selector Lever Cable, Removing and Installing, through 02/2009”, page 64 .
❑ Checking. Refer to ⇒ “5.5 Selector Lever Cable, Checking”, page 80 .
❑ Adjusting. Refer to ⇒ “5.6 Selector Lever Cable, Adjusting”, page 80 .
12 - Hex Nut with Collar
❑ 8 Nm
❑ Quantity: 4
5.2 Selector Lever Cable, Removing and In‐

stalling, through 02/2009
Note
After installation, the selector lever cable must be checked for

ease of movement and adjusted.
Removing
– Move the selector lever into “S”.

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Loosen the adjusting screw -arrow-.
Note
Use pliers to remove the lock washer -B- from the cable bracket.
Do not use a sharp-edged lever. This could damage the selector
lever cable rubber grommet.
– Remove the lock washers -A and B-. The lock washers must
later be replaced when adjusting the selector lever cable.
– Raise the vehicle.
To remove the selector level cable or the selector mechanism, the
heat shield under the selector mechanism must be removed as
follows:
Caution
Risk of damaging the decoupling element.

♦ Do not bend the decoupling element more than 10°.
♦ Do not load the decoupling element.
♦ Do not damage the wire mesh on the decoupling element.
– Loosen the nuts on the clamping sleeve -1- and then slide it
toward the rear.
– Remove the front tunnel brace -arrows- from the underbody.
– If necessary remove the exhaust system bracket from the

subframe -arrows-.
– Tie up the front exhaust pipe.
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– If equipped, remove nuts -1 and 2-, and remove the rear tunnel
brace.
– Disengage the center muffler and the rear muffler from the re‐
taining loops -arrows- and tie them to the body for example
with a wire. Remove the exhaust system rear section, if nec‐
essary.
– Remove the underbody trim panel nuts -arrows-.

– Remove the lock washers -2 and 3-.
– Lower the underbody trim panel on the inside just enough until
the heat shield -1- for the center tunnel can be removed.
– Remove the -selector housing- from under the selector lever.
– Remove the locking plate on the cable mounting bracket. Al‐

ways replace the locking plate.

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The -shift housing- is pushed forward slightly on the selector lever

cable.
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The locking strap must be pushed forward in order to remove the

selector lever cable in direction of -arrow 1-.
– Push the -pin- upward with a screwdriver at the same time in
direction of -arrow 2-.
– Insert the -screwdriver- from underneath while pushing the

securing tab forward.

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For Clarity
– Remove the selector lever cable.

Remove the selector lever cable from the selector housing.
Installing
Do not lubricate the selector lever cable.
– Route the selector lever cable making sure it is without ten‐
sion. Install also into the cable bracket on the transmission. Do
not secure yet with the lock washers. Do not clip in the ball
head.
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– When installing, make sure the selector lever cable is routed

correctly.
If the heat shield underneath is bent, there will be noises. The
selector lever cable will then »flap« on the heat shield.
– Pay attention to the heat shield. Push it upward into the tunnel
in the direction of -arrow-.
– Position the selector housing on the selector lever cable.
– Install the selector lever cable into the selector mechanism.

– Insert the selector lever cable into the bracket and then insert
the bolt through the eye from the top in the direction of
-arrow 2-.
Install the locking plate only after having checked the selector
lever cable for ease of movement. Refer to
⇒ “5.5 Selector Lever Cable, Checking”, page 80 .
– Secure the selector lever cable with a new securing plate to

the cable bracket on the selector mechanism.

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– Install the selector housing.
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– Install the heat shield -1- under the selector mechanism and
attach with the lock washers -2 and 3-.
– Attach the underbody trim panel to the body -arrows-.
– Install the exhaust system and align it without tension. Refer
to ⇒ Rep. Gr. 26 .
– Install the tunnel braces under the exhaust system. Refer to
⇒ Body Exterior; Rep. Gr. 50 ; Tunnel Brace .
– Adjust the selector lever cable after installing. Refer to
5.3 Overview - Selector Mechanism, Vehicles from 03/2009
1 - Shift Cover with Handle

❑ Do not remove the han‐
dle unnecessarily. Only
the cover must be un‐
clipped for the emergen‐
cy release. Refer to
page 82 .
❑ Pull the button past its
pressure point before
removing the handle.
Secure the button with a
cable tie or some suita‐
ble wire. This prevents
the locking button from
being pushed back into
knob accidentally.
❑ Selector lever handle,
Removing and instal‐
ling. Refer to
⇒ “5.8 Selector Lever
Handle, Removing and
Installing”, page 82 .
2 - Selector Mechanism with
Selector Lever and Selector
Lever Cable
❑ With integrated Selector
Lever Sensor System
Control Module - J587-
with Selector Lever -
E313- , Tiptronic Switch
- F189- , Selector Lever
Park Position Lock
Switch - F319- and Shift
Lock Solenoid - N110- .
❑ The selector lever cable
can only be replaced to‐
gether with the selector
mechanism

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❑ Do not grease the selector lever cable.
❑ Removing and installing. Refer to
⇒ “5.4 Selector Mechanism, Removing and Installing, Vehicles from 03/2009”, page 73 .
❑ Checking. Refer to ⇒ “5.5 Selector Lever Cable, Checking”, page 80 .
❑ Adjusting. Refer to ⇒ “5.6 Selector Lever Cable, Adjusting”, page 80 .
3 - Bolt
❑ 8 Nm
4 - Hex Nut with Collar
❑ 8 Nm
❑ Quantity: 4
5 - Gearshift Housing
❑ Available only together with the selector mechanism. Refer to the Parts Catalog.
6 - Adjusting Bolt
❑ 13 Nm
7 - Lock Washer
8 - Locking Plate
5.4 Selector Mechanism, Removing and In‐

stalling, Vehicles from 03/2009
⇒ “5.4.1 Selector Mechanism with Selector Housing, Removing
and Installing”, page 73
⇒ “5.4.2 Selector Mechanism without Selector Housing, Remov‐
ing and Installing”, page 77
5.4.1 Selector Mechanism with Selector

Housing, Removing and Installing
Brief Description
The selector mechanism and the selector lever cable must be
separated from each other. Both are removed with the selector
housing.
Remove the center console inside the vehicle interior.
It is necessary to remove the heat shield under the vehicle.
It is possible to remove and install the selector mechanism with
selector lever cable alone without the selector housing. Refer to
⇒ “5.4.2 Selector Mechanism without Selector Housing, Remov‐
ing and Installing”, page 77 .
Note
After installation, the selector lever cable must be checked for

ease of movement and adjusted.
Removing
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– Remove the selector lever handle and disconnect the con‐

nector -2- from the cover while doing so. Refer to
⇒ “5.8 Selector Lever Handle, Removing and Installing”, page
82 .
– Remove the center console. Refer to ⇒ Body Interior; Rep.
Gr. 68 ; Center Console .
– Disconnect the connector -1- from the selector mechanism to
the vehicle wiring harness.
– Remove the air filter housing:
♦ Gasoline engine. Refer to ⇒ Rep. Gr. 24 ; Air Filter; Air Filter
Housing, Removing and Installing .
♦ TDI engine. Refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection
System; Air Filter Housing, Removing and Installing .
Note
To remove the selector level cable or the selector mechanism, the
heat shield under the selector mechanism must be removed as
follows:
Caution


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– Loosen the nuts on the clamping sleeve -1- and then slide it
toward the rear.
– Remove the front tunnel brace -arrows- from the underbody.
– If necessary remove the exhaust system bracket from the

subframe -arrows-.
– If equipped, remove nuts -1 and 2-, and remove the rear tunnel
brace.
– Disengage the center muffler and the rear muffler from the re‐
taining loops -arrows- and tie them to the body for example
with a wire. Remove the exhaust system rear section, if nec‐
essary.
– Remove the underbody trim panel nuts -arrows-.

– Remove the lock washers -2 and 3-.
– Lower the underbody trim panel on the inside just enough until
the heat shield -1- for the center tunnel can be removed.
Note
A second technician is required under the vehicle to remove the

selector mechanism.
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– Remove the nuts -arrows- in the vehicle interior.

– Remove the bracket -A-, if equipped.
– Remove the selector mechanism -B- with the selector lever
cable and selector housing downward.
Installing
Install in reverse order of removal.
Note
♦ Do not bend or kink the selector lever cable.

♦ Do not lubricate the selector lever cable.
♦ Tightening specifications. Refer to
⇒ “5.3 Overview - Selector Mechanism, Vehicles from
03/2009”, page 72 .
– Install the heat shield -1- under the selector mechanism and
attach with the lock washers -2 and 3-.
– Attach the underbody trim panel to the body -arrows-. Refer to
⇒ Body Exterior; Rep. Gr. 50 ; Underbody Trim Panels .
– Install the exhaust system and align it without tension. Refer
to ⇒ Rep. Gr. 26 .
– Install the tunnel braces under the exhaust system. Refer to
⇒ Body Exterior; Rep. Gr. 50 ; Tunnel Brace .
– Install the center console. Refer to ⇒ Body Interior; Rep. Gr.
68 ; Center Console .
– Install the selector lever handle. Refer to
82 .
– Adjust the selector lever cable. Refer to
– Check the selector mechanism. Refer to
⇒ “5.10 Selector Mechanism, Checking”, page 86 .
– Install the air filter housing:

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5.4.2 Selector Mechanism without Selector

Housing, Removing and Installing
Brief Description
The selector mechanism and the selector lever cable must be
separated from each other. Both are removed together.
Remove the center console inside the vehicle interior.
A cord is attached to the selector lever cable prior to removal. The
cord is used to remove and install the selector lever cable be‐
tween the tunnel and the heat shield.
The selector mechanism with selector lever cable can be re‐
moved and installed together with the selector housing. Refer to
⇒ “5.4.1 Selector Mechanism with Selector Housing, Removing
and Installing”, page 73 .
Removing
– Remove the selector lever handle and disconnect the con‐

nector -2- from the cover while doing so. Refer to
82 .
– Remove the center console. Refer to ⇒ Body Interior; Rep.
Gr. 68 ; Center Console .
– Disconnect the connector -1- from the selector mechanism to
the vehicle wiring harness.
– Remove the air filter housing:
♦ Diesel engine. Refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection
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Note
– Attach a longer cord to the end of the selector lever cable. The
cord is used to guide the selector lever cable between the tun‐
nel and the heat shield during installation.
– Remove the four bolts attaching the selector mechanism to the

selector housing.

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– Pull the selector mechanism and selector lever cable carefully

out of the center tunnel. Make sure the cord is pulled through
far enough so that it can reached from inside the engine com‐
partment.
– Remove the selector lever cable cord.
Note
The selector mechanism is available only together with the se‐

lector housing and selector lever cable. Refer to the Parts Cata‐
log.
Installing
Install in reverse order of removal. Note the following:
A second technician is needed for threading the selector lever
cable from the passenger compartment into the engine compart‐
ment.
Note

♦ Do not lubricate the selector lever cable.
♦ Tightening specifications. Refer to
⇒ “5.3 Overview - Selector Mechanism, Vehicles from
03/2009”, page 72 .
– Secure the cord that was involved when removing the selector
mechanism from the engine compartment on the end of the
selector lever cable.
– Guide the selector mechanism and selector lever cable
through the opening in the center tunnel.
– From the engine compartment, have the second technician
pull the cord with the selector lever cable through the tunnel
until it is possible to attach the selector lever cable to the cable
bracket.
– Remove the selector lever cable cord.
– Attach the selector mechanism to the selector housing with

four bolts.
– Install the center console. Refer to ⇒ Body Interior; Rep. Gr.
68 ; Center Console .
– Install the selector lever handle. Refer to
82 .
– Check the selector mechanism. Refer to
⇒ “5.10 Selector Mechanism, Checking”, page 86 .
– Install the air filter housing:
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5.5 Selector Lever Cable, Checking

Brief Description
The selector lever cable must be removed from the transmission
in order to check it for ease of movement. Do not let the removed
end touch anything.
Then the selector lever is moved and the selector lever cable in‐
stalled again on the transmission.
After that, the selector lever cable must be adjusted. Refer to
Do not lubricate the selector lever cable connections.
Checking
– Move the selector lever into »P«.
– Remove the selector lever cable from the lever on the trans‐
mission.
– Move the selector lever from »P« to »S« and back to »P« sev‐
eral times.
• The selector lever must have ease of movement.
– Install the selector lever cable with new lock washers and the
»loosened« adjustment screw.
5.6 Selector Lever Cable, Adjusting

Selector Lever Cable Must Always Be Adjusted If:
♦ The selector lever cable was removed from the transmission.
♦ The engine and/or transmission were removed and installed.
♦ Sections of the subframe mount were removed and installed.
♦ The selector lever cable itself or the selector mechanism was
removed and installed.
♦ The engine/transmission position was changed, for example,
were installed without tension.
Adjusting

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Move the Lever on the Transmission into “P”.

The lever on the transmission must be pushed »all the way to the
rear«.
– Pull the lever forward.
– Push the lever »to the rear« -arrow-.

“P” is in the Second Detent.
Note
♦ Raise the vehicle to make sure the transmission is in “P” (park‐

ing lock is engaged). The front wheels must not turn together
in any direction.
♦ The transmission is also in “P” if the vehicle does not move
with wheels spinning freely.
– Install the selector lever cable with the loosened adjusting

screw -arrow- and the new lock washer -A and B-.
– Tap the handle on the selector lever back and forth gently but
do not move it out of “P” under any circumstances.
This places the selector lever cable core in its optimal position.
– Tighten the adjusting bolt -arrow- to 13 Nm.
This ends the adjustment.
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5.7 Selector Lever, Emergency Release

Do Not Remove the Handle
– Unclip the shift cover and hold it to the side.
– Press the brake or set the parking brake.
Vehicles through 02/2009
– Press on the yellow plastic piece from the right to the left in
direction of -arrow-.
– Or press it onto the solenoid pins.
Vehicles from 03/2009

– Push onto the yellow plastic part -arrow-.
5.8 Selector Lever Handle, Removing and

Installing
Brief Description
There are different handles depending on the model.
The handle is removed together with the shift cover.
Removing
– Move the selector lever into “D” position.

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Handle with Side Button

– Pull the button out of the handle just far enough until a small
gap is visible between the handle and the button. The button
locks when released.
– Secure the button in this position with a cable tie or wire to
prevent the button from being pressed in.
Handle with Front Button

– It is not necessary to pull out the button by hand. The button
locks in the installation position -arrow- when the handle is re‐
moved.
Vehicle with Sleeve

– Unclip the cover.
Disconnect the connector from the shift cover.
Push the sleeve upward in direction of -arrow- to unlock the han‐
dle.
Vehicle with Clamp

– Cut the clamp under the boot -arrow- with a side cutter.
All Handles
– Remove the handle from the selector lever without pushing the
button.
Note
Do not push the button once the handle has been removed oth‐
erwise it will not be possible to install the handle again.
Installing
– Install in reverse order of removal while noting the following:
• The selector lever is in the “D” position.
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Handle with Side Button

• The button inside the handle is pulled out and if necessary is
protected from getting pushed in again.
Handle with Front Button

• The button is in the installation position -arrow-.
If the button was pushed in by mistake, the installation position
can be set again.
– Move the button into the installation position. Refer to
page 85 .
Note
A new handle is delivered with an assembly fastener. Remove

the retainer just before installing.
Vehicle with Sleeve

– Install the handle all the way onto the selector lever and lock
it.
– Push the sleeve downward to lock it.
Vehicle with Clamp
– Install the handle all the way with a new clamp.
– Clamp off the clamps using Hose Clamp Pliers - VAG1275- .
– Press the button after installation.
Note
If the button stays in the handle after being pressed, this means
it was installed incorrectly. If this happens, remove the handle
again and move the button in the installation position again. Refer
to
page 85 . Then the handle can be installed again.
Further installation is performed in reverse order of the removal.

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5.9 Button in Handle, Moving into Installa‐

tion Position
⇒ “5.9.1 Handle with Side Button”, page 85
⇒ “5.9.2 Handle with Front Button”, page 85
5.9.1 Handle with Side Button

– Pull the button out of the handle just far enough until there is
a small gap between the handle and the button. The button
locks when released.
– Secure the button in this position with a cable tie or wire to
prevent the button from being pressed in.
5.9.2 Handle with Front Button

The button cannot be pulled out on these handles.
There are two ways to move the button into the installation posi‐
tion, »with« or »without« the assembly fastener. Both possibilities
are described here.
Move the Handle »with« an Assembly Fastener into the Installa‐
tion Position:
When using an assembly fastener, make sure that it has an eye
-arrow- at the front. Other assembly fasteners are not suitable.
– With the button pressed and push the assembly fastener (with
the eye) -arrow- all the way in until it latches into the assembly
fastener. Then release the button. The button locks into the
installation position when the assembly fastener is pulled out.
Moving the Handle »without« an Assembly Fastener into the In‐
stallation Position:
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– Carefully unclip the handle trim -A- upward.
– Push the small lever -1- for the pull rod into the groove -2- with
a screwdriver. This pushes the button -3- into the installation
position.
-I- the button is in the pressed position
-II- the button is in the installation position
Note
♦ Push the lever into the groove and no farther.

♦ Clip the handle trim back onto the selector mechanism only
after the handle is installed. This way it is possible to see if the
small lever engages into the pull rod when the button is push‐
ed.
5.10 Selector Mechanism, Checking

Do not operate the starter when the selector lever is in “R”, “D”
and “S”.
If the selector lever position “N” is selected at speeds greater than
km/h (3.1 mph), the shift lock solenoid must not engage and block
the selector lever. The selector lever can be shifted into another
gear.
When shifting into the selector lever position “N” at speeds below
km/h (3.1 mph) (almost stopped), the shift lock solenoid may en‐
gage only after approximately one second. The selector lever can
only be moved out of “N” when the brake pedal is pressed.
Selector Lever in “P” and the Ignition Turned On:
• If the brake pedal is not depressed:

The selector lever is locked and cannot be moved out of “P” when
the button is pressed. The shift lock solenoid blocks the selector
lever.
• If the brake pedal is depressed:
The shift lock solenoid releases the selector lever. It is possible
to select a gear. Move the selector lever slowly from “P” through
“S”; while doing this, check whether the selector lever position

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displayed in instrument cluster matches actual selector lever po‐

sition.
Selector Lever in “N” and Ignition Switched On
• If the brake pedal is not depressed:
The selector lever is locked and cannot be moved out of “P” when
the button is pressed. The shift lock solenoid blocks the selector
lever.
• If the brake pedal is depressed:
The shift lock solenoid releases the selector lever. It is possible
to select a gear.
Selector Level in the “tiptronic” Position
• Move the selector lever into the tiptronic gate:
The illuminated “D” symbol in the selector mechanism cover must
turn off. The “+” and “-” must turn on.
The transmission range display in the instrument cluster must
change from “P R N D S” to “6 5 4 3 2 1” when the selector lever
is moved into the Tiptronic gate.
The Ignition and Lights Must Be Turned On
The respective symbol is being lit up in the selector mechanism
cover.
Transmission Range Display
Simultaneous lighting of all segments on the transmission range
display indicates the transmission is in emergency mode.
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6 Transmission, Removing and Instal‐

ling, Jetta from MY 2005 , Golf Wag‐
on from MY 2007 and Golf Wagon
from MY 2010
⇒ “6.1 Transmission, Removing”, page 88 .
⇒ “6.2 Transmission, Installing”, page 97 .
6.1 Transmission, Removing

Brief Description
The transmission is removed downward separately.
Remove the battery, the air filter and the starter »from above«.
Coolant hoses are clamped off. Before removing the subframe
mount, the engine and transmission must be supported.
»From underneath«:
The -subframe-, with the -pendulum support-, with the
-steering gear- and with -both control arms- are removed togeth‐
er.
Removing the -subframe-. Refer to ⇒ Rep. Gr. 40 . If done cor‐
rectly, the subframe can be removed and installed without the
customer experiencing increased tire wear later. It is recommen‐
ded to read this information »prior« to removing the transmission.
In this way, -subframe- can be secured and removed correctly.
The Locating Pins - T10096- will be needed.
If the -subframe- is not secured by the pins, then later an axle
alignment will be necessary.
In this case, an axle alignment is unnecessary and expensive ad‐
ditional work! It would be a lot of work and an unnecessary charge
for the customer!
Installing the Locating Pins - T10096- is simple. It is very useful
though.

♦ Engine Support Bridge - 10-222A-
♦ Transmission Support - Mounting Plate 42A - 3282/42A-
♦ Engine Support Bridge - Engine Support Feet - 10-222A/8-
♦ Engine Support Bridge - Engine Support 3 - 10-222A/3-
♦ Transmission Support - 3282-
♦ Insert Tool - 18mm - T10179-
♦ Hose Clamps - Up To 40mm - 3093- (Quantity 2)
♦ or Hose Clamps - Up To 25 mm - 3094- (Quantity 2)
♦ Transmission Support - Pins 29 - 3282/29-
♦ Engine and Gearbox Jack - VAS6931-
♦ Engine Support Bridge - Gearbox Bracket - T10346-
Removing

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Note
To perform work sequence, the ground cable must be discon‐

nected from battery. Check if a coded radio is installed. If neces‐
sary, obtain the anti-theft coding beforehand.

Connecting .
stalling .
– Remove the selector lever cable from the transmission

-arrows-.
Note
Use pliers to remove the lock washer from the cable bracket. Do
not use a sharp-edged lever. This could damage the selector lev‐
er cable rubber grommet.
Both lock washers must later be replaced when adjusting selector

lever cable.
Remove the selector lever cable very carefully from the transmis‐
sion cable bracket. Do not bend the selector lever cable at the
same time.
The selector lever cable can also be slid back slightly from the
cable bracket and later removed when lowering transmission.
Watch the selector lever cable when lowering the transmission.
During later installation, only clip in the »new« lock washers after
the selector lever cable has been checked and adjusted. Refer to
⇒ “5.5 Selector Lever Cable, Checking”, page 80 .
6. Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and Golf Wagon from MY 2010 89
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– Disconnect the coolant hoses with Hose Clamps - Up To

25mm - 3094- and remove them from the transmission fluid
cooler.
– Seal the transmission fluid cooler with clean plugs.
– Remove the starter -A-. Refer to ⇒ Electrical Equipment; Rep.

Gr. 27 ; Starter; Starter, Removing and Installing .
Remove the »lower« starter bolt first.
Caution


– Route the wires near the transmission cover upward and tie
them up.
– Remove all the upper bolts between the engine and the trans‐
mission.
These tools are suitable for this.

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Note
On some transmissions a bolt is located in the starter hole

-arrow-.
– Remove both filler pieces from the left and right fender upper
edges.
– If there are hose and cable connections located near the en‐
gine lifting eyes for the Engine Support Bridge - 10-222A- ,
these must now be removed.
Check in following engine types which tool is needed to support
the engine.
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1.9L TDI Engine

– Support the engine and transmission. Do not raise them.
Engine Support - Automatic Transmission Adapter - 10-222A/16-

♦ Engine Support Bridge - Additional Hooks (2 pc.) - 10-222A/
2-
♦ Engine/Gearbox Support Shackle (2 pc.) - 10-222A/12-
2.0L TDI Engine - Jetta from MY 2005 and Golf Wagon from MY
2007
♦ Engine Support - Bracket w/Spindle and Hook - 10-222A/10-
2.0L TDI Engine - Golf Wagon from MY 2010


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1.4L TSI Engine

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2.0L TFSI Engine

– Attach the Engine Support Bridge - Gearbox Bracket -
T10346- to the rear hole of the three locating holes for the
battery tray.
– Use a M6 collar bolt or one of the bolts for the battery tray.

»flat side« toward engine compartment
♦ Use the Engine Support Bridge - Spindle Spacer - 10-222A/
17- on the »front« spindle.
Continuation for All Engines
– Pretension the engine/transmission assembly with the spin‐
dles, but do not lift.
– Loosen left and right front wheel bolts.
– Lift the vehicle, all four mounts from lifting platform at the same
height.
– Remove the front wheels.
– Remove the lower section of the left front wheel housing liner.
Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Wheel Housing Liner;
Overview - Front Wheel Housing Liner .
– Remove the heat shield above the right drive axle -arrows-, if
equipped.
Caution


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– Disconnect the exhaust system at the clamping sleeve and

remove the bracket for the exhaust system from the subframe
-arrows-. Refer to ⇒ Rep. Gr. 26 .
– Remove the pendulum support from the transmission.
– Secure the subframe. Refer to ⇒ Suspension, Wheels, Steer‐

ing; Rep. Gr. 40 ; Subframe; Subframe, Securing .
Note
If the -subframe- is not secured, a vehicle alignment must be per‐

formed later.
– Remove the subframe and steering gear. Refer to ⇒ Suspen‐

sion, Wheels, Steering; Rep. Gr. 40 ; Subframe
– Remove the drive axles from the transmission. Refer to ⇒
Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles, Re‐
moving and Installing .
– Tie the right drive axle as high up as possible.

– Move the left drive axle to the rear and secure it. Be careful
not to damage the surface protection.
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– There may be a small cover plate on the plate between the

engine and transmission above the right flange shaft. Remove
the cover plate -A-.

-A-.
– Then lower the engine/transmission slightly using the Engine
Support Bridge - 10-222A- spindles so that the transmission
– Remove the transmission bracket in direction of -arrow-.

To remove the transmission 02E, the Transmission Support -
3282- is equipped with the Transmission Support - Mounting Plate
- 3282/42A- and positioned on the Engine and Gearbox Jack -
VAS6931- .

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– Align the arms of the Transmission Support so that they match

up with the holes in the Transmission Support - Mounting Plate
42A - 3282/42A- .
– Install the mounting element as illustrated on the Transmission
Support - Mounting Plate 42A - 3282/42A- .
– Place the Engine and Gearbox Jack - VAS6931- under the
vehicle.
• The arrow symbol on the Transmission Support - Mounting
Plate 42A - 3282/42A- points in the direction of travel.
– Align the Transmission Support - 3282- so that it is parallel to
the transmission.
– Install the Transmission Support - Pins 29 - 3282/29- in the
transmission.
– Secure both the other support elements to the transmission as
shown.
Note
♦ Deviating from the illustration of the Adjusting Plate the front

transmission support is illustrated mounted to the transmission
-arrow-.
♦ DSG® transmission 02E “AWD” is shown in the illustration.
The mounting elements on the “FWD” are identical.
– Support the transmission by lifting it from underneath using the

Engine and Gearbox Jack - VAS6931- .
The transmission is disconnected from the engine in this position.
– Remove the remaining engine/transmission connecting bolts.
– Remove transmission from engine »while being careful of se‐
lector lever cable« and lower the transmission.
Note
Pay attention to all of the lines when lowering the transmission.
Transport the transmission and secure to the assembly stand.

Refer to
Install the transmission. Refer to
⇒ “6.2 Transmission, Installing”, page 97 .
6.2 Transmission, Installing

Install in reverse order of removal. Nevertheless, important steps
should be named here:
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Note
♦ Always replace the needle bearing -arrow- after separating the

engine and transmission.
♦ If the needle bearing in the crankshaft is damaged, the gears
will no longer shift correctly.
– Replace the needle bearing in the crankshaft. Refer to ⇒ Rep.

Gr. 13 ; Crankshaft; Needle Bearing in Crankshaft, Replacing .
– Transmission pins (not splines) on the driveshaft must also be
lightly lubricated.
– Make sure both alignment sleeves between the engine and
the transmission are correctly seated.
– Make sure the intermediate plate fits correctly.
– Guide the selector lever cable into the cable bracket as soon
as possible.
Check the selector lever cable when raising the transmission. Do
not fail to place it in the cable mounting bracket »early«.
Do not grease the selector lever cable.
Guide the engine and transmission together by hand until the en‐
gine flange and transmission flange come into contact with one
another all around.
If they do not, »something is incorrect«!
– Adjust the transmission mount until the engine and transmis‐
sion »are in alignment«.
– Turn the crankshaft slightly if necessary.
– Insert the transmission without pinching any lines.
– Attach the transmission to the engine. Transmission to engine
tightening specifications. Refer to

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Install the left subframe mount as follows:

– Replace all bolts -1 and 2- for the left subframe mount.
– Fasten the transmission bracket -A- to the transmission using
the bolts -1-.
– The align the engine/transmission in its installation position.
Lift until the transmission bracket is touching the transmission
mount completely.
Caution
There is a risk of damaging the threads in transmission bracket

by inserting the bolts at an angle.
♦ Before installing the bolts -2-, the transmission bracket
and transmission mount support arm must be absolutely
parallel to each other. If necessary, lift the back of the
transmission using the Engine and Gearbox Jack .
Install the engine/transmission mount without tension. Refer to ⇒

Rep. Gr. 10 .
– Tighten the bolts -2- to the tightening specification.
WARNING
Only remove the Engine Support Bridge - 10-222A- when all

the left and right subframe mount bolts are tightened to the
tightening specification.
– Remove the Engine Support Bridge - 10-222A- .

– Install the starter. Refer to ⇒ Electrical Equipment; Rep. Gr.
27 ; Starter; Starter, Removing and Installing .

– The arrow -D- on the DSG Transmission Mechatronic - J743-
-B- must line up with the connector -A- as well as with the tab
-C-.
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– Selector lever cable lock washers -arrows- must be replaced.

– Always adjust the selector lever cable. Refer to
Gr. 19 ; Cooling System Components .
– Attach the drive axles to the transmission. Refer to ⇒ Sus‐
pension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles, Re‐
– Install the heat shield above the right drive axle, if equipped.
At the same time tighten the bolts -1- to 25 Nm.
– Install the subframe and steering gear. Refer to ⇒ Suspen‐
sion, Wheels, Steering; Rep. Gr. 40 ; Subframe
– Assemble the exhaust system and install the exhaust system
bracket to the subframe. Refer to ⇒ Rep. Gr. 26 .
– Install the lower section of the left front wheel housing liner.
– Install the battery tray and the battery. Refer to ⇒ Electrical
stalling .
– Install the air filter housing.
stalling .
– Install the front wheels. Refer to ⇒ Suspension, Wheels,
Steering; Rep. Gr. 44 ; Wheel Installation Tightening Specifi‐
cations .
6.3 Tightening Specifications

Engines: 1.9L TDI; 2.0L TDI; 2.0L TFSI
Note
The -arrows- point to the alignment sleeves in the engine.

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M12 - 80 Nm
❑ When using the Insert
Tool - 18mm - T10179- :
65 Nm.
M10 - 40 Nm
Continuation for All Engines

– Tighten the transmission bracket -A- to the transmission to 40
Nm + 90° using the bolts -1-.
– Tighten the bolts -2- to 60 Nm + 90°.
Note
Pry the transmission bracket into the correct seat using a screw‐
driver while tightening the bolts -2-.
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7 Transmission, Removing and Instal‐

ling, Jetta from MY 2011
⇒ “7.1 Transmission, Removing, Jetta MY 2011 with 2.0L 103 kW
Diesel”, page 102 .
⇒ “7.2 Transmission, Installing, Jetta MY 2011 with 2.0L 103 kW
⇒ “7.3 Transmission, Removing, Jetta MY 11, 2.0L 147 kW Gas‐
oline Engine”, page 115 .
⇒ “7.4 Transmission, Installing, Jetta MY 11, 2.0L 147 kW Gaso‐
line Engine”, page 127 .
7.1 Transmission, Removing, Jetta MY

2011 with 2.0L 103 kW Diesel
Brief Description
»From above«:
The battery, air filter and starter are removed. The steering gear
wiring harness is disconnected and »freed up«. This way it can
be lowered together with the subframe and the steering gear. En‐
gine and transmission are supported before the left subframe
mount is removed.
er.

Locating Pins - T10096- and Subframe Locking Pin (2 pc.) -
T10452- will be needed.
for the customer!
Installing the Locating Pins - T10096- and Subframe Locking Pin
(2 pc.) - T10452- is simple. It is very useful though.


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♦ Hose Clamps - Up To 25mm - 3094- or Hose Clamps - Up To
40mm - 3093-
♦ Tensioning Strap - T10038-
♦ Engine Support - Basic Set - T40091-
♦ Engine Support - Supplement Kit - T40093A-
Removing
Note


Connecting .
– Remove the engine cover. Refer to ⇒ Rep. Gr. 15 ; Cylinder
Head; Engine Cover, Removing and Installing .
– Remove the complete air filter housing. Refer to ⇒ Rep. Gr.
23 ; Diesel Direct Injection System; Overview - Air Filter .

Connecting .
7. Transmission, Removing and Installing, Jetta from MY 2011 103

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-arrows-.
Note
♦ Use pliers to remove the lock washer from the cable bracket.
Do not use a sharp-edged lever. Otherwise the selector lever
cable could get damaged.
♦ Remove the cable bracket -2- from the transmission, if nec‐
essary. Remove the bolts -1- and the lock washer -3-.
♦ Replace the bolts -1- and the lock washers.
♦ Bolt tightening specification -1- 20 Nm +90°.
Caution
Risk of damaging the selector lever cable.

♦ Remove the selector level cable from the cable bracket
when lowering transmission.

Note

warm.
– Clamp the coolant hoses with Hose Clamps - Up To 25mm -

3094- or Hose Clamps - Up To 40mm - 3093- and remove the
hoses from the transmission fluid cooler.
– Seal off the transmission fluid cooler connections with sealing
plugs taken from for example the Engine Bung Set -
VAS6122- .

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Remove the »lower« bolt first.
Caution


them up.
mission.

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One bolt is located inside the hole for the starter -arrow-. Use
Socket - Xzn 14 - T10061- to remove the bolt.
– Remove the plenum chamber cover. Refer to ⇒ Body Exterior;
Rep. Gr. 50 ; Plenum Chamber Cover; Plenum Chamber
Cover, Removing and Installing .

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– Remove the bolts -arrows- for the left and right lock carrier
retaining brackets.
– Remove the lower mounts on the Engine Support Bridge - En‐

gine Support 28 - 10-222A/28- and replace them with the
Engine Support Bridge - Engine Support 28-2 - 10-222A/
28-2- .
– Remove the bolts -arrows- for securing the engine support
bridge on the lock carrier from the Engine Support Bridge -
Engine Support 28-2 - 10-222A/28-2- .
• Use the bolts present in the Engine Support Bridge - Engine
Support 28-2 - 10-222A/28-2- for attaching the Engine Support
Bridge - Engine Support 28 - 10-222A/28- . Not the bolts for
the retaining bracket.
– Install the Engine Support Bridge - Engine Support 28 -

10-222A/28- and tighten the bolts to 8 Nm -arrows-.
Caution
A second technician is needed to mount the Engine Support

Bridge on the vehicle to prevent the Engine Support Bridge
from tipping.
Install the Engine Support Bridge - 10-222A- as shown.

– First slide the Moveable Joints -2- onto the Square Pipe from
the Engine Support Bridge - 10-222A- .
– Mount the Engine Support Bridge - 10-222A- on the suspen‐
sion strut towers and have a second technician hold it to
prevent it from tipping.
– Push the Engine Support - Basic Set - Square Pipe -
T40091/1- - 6- from the front left and right through the Engine
Support Bridge - Engine Support 28 - 10-222A/28- - 7- and
place on each side of the Engine Support - Supplement Kit -
Movable Joint - T40093/4- - 5-.
– Slide the Engine Support - Basic Set - Rail with Holes -
T40091/2- - 4- with the Engine Support - Supplement Kit -

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Mount - T40093/5- -9- in the Engine Support - Supplement Kit

- Moveable Joint - T40093/4- - 5-.
– Install the locking pins into the Engine Support - Basic Set -
Rail with Holes - T40091/2- -4- and secure it with the cotter
pins.
1 - Engine Support Bridge - En‐

gine Support 31 - Adapter 2 -
10-222A/31-2-
2 - Engine Support - Basic Set
- Moveable Joint - T40091/3-
10-222A/31-1-
- Rail with Holes - T40091/2-
5 - Engine Support - Supple‐
ment Kit - Movable Joint -
T40093/4-
- Square Pipe - T40091/1-
gine Support 28 - 10-222A/28-
with Engine Support Bridge -
Engine Support 28-2 -
10-222A/28-2-
8 - Engine Support Bridge -
Spindle - 10-222A/11-
ment Kit - Mount 5 - T40093/5-
10 - Engine Support - Bracket
w/Spindle and Hook -
10-222A/10-
– Tighten all the threaded connections on the Engine Support

Bridge - 10-222A- hand-tight. While doing so, adjust the height
of the Engine Support Bridge - 10-222A- parallel over the En‐
gine Support Bridge - Engine Support 28 - 10-222A/28- .
– Pretension the engine/transmission assembly with the spin‐
dles, but do not lift.
height.
– Remove the left front housing liner. Refer to ⇒ Body Exterior;
Housing Liner .

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Caution

– Separate the exhaust system at the clamping sleeve and re‐

move the bracket from the subframe -arrows-. Refer to ⇒ Rep.
Gr. 26 .
– Remove the bolts -11- and then remove the pendulum support
– Secure the subframe before removing. Refer to ⇒ Suspen‐

sion, Wheels, Steering; Rep. Gr. 40 ; Subframe; Subframe,
Securing .
Note

formed later.

sion, Wheels, Steering; Rep. Gr. 40 ; Subframe .

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– Remove the heat shield above the right drive axle -arrows-.


this cover plate -A-, if equipped.

-A-.
Support Bridge - 10-222A- spindles so that the transmission

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VAS6931- .
– Align the arms of the Transmission Support - 3282- so that
they match up with the holes in the Transmission Support -
Mounting Plate 42A - 3282/42A- .
vehicle.
the transmission.
transmission.
shown.
Note

-arrow-.

Note

Refer to
⇒ “7.2 Transmission, Installing, Jetta MY 2011 with 2.0L 103 kW

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7.2 Transmission, Installing, Jetta MY 2011

with 2.0L 103 kW Diesel
Note
Refer to “Transmission, Removing”

⇒ “7.1 Transmission, Removing, Jetta MY 2011 with 2.0L 103 kW
Diesel”, page 102 for a list of the special tools needed.

Note


lightly lubricated.
as possible.
another all around.

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the bolts -1-.
mount completely.
Caution


Rep. Gr. 10 ; Subframe Mount .
– Tighten the bolts -2- to the tightening specification. Refer to
WARNING



-C-.
– Install the heat shield over the right drive axle. Refer to ⇒
Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles,
Overview and Servicing; Drive Axle Heat Shield .

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Gr. 19 .
– Assemble the exhaust system and then attach the exhaust
system bracket to the subframe. Refer to ⇒ Rep. Gr. 26 .
– Install the plenum chamber cover. Refer to ⇒ Body Exterior;
– Install the bolts -arrows- for the left and right lock carrier re‐
taining brackets to the tightening specification. Refer to ⇒
Body Exterior; Rep. Gr. 50 ; Lock Carrier; Lock Carrier - At‐
tachments .
stalling .
– Install the air filter. Refer to ⇒ Rep. Gr. 23 ; Diesel Direct
Injection System; Overview - Air Filter .
– Install the engine cover. Refer to ⇒ Rep. Gr. 15 ; Cylinder
– Install the left front housing liner. Refer to ⇒ Body Exterior;
Rep. Gr. 66 ; Wheel Housing Liner; Front Wheel Housing Lin‐
er, Removing and Installing .
cations .
7.3 Transmission, Removing, Jetta MY 11,

2.0L 147 kW Gasoline Engine
Brief Description
»From above«:
The battery, air filter and starter are removed. The steering gear
wiring harness is disconnected and »freed up«. This way it can
be lowered together with the subframe and the steering gear. En‐

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gine and transmission are supported before the left subframe

mount is removed.
er.

Locating Pins - T10096- and Subframe Locking Pin (2 pc.) -
T10452- will be needed.
for the customer!
Installing the Locating Pins - T10096- and Subframe Locking Pin
(2 pc.) - T10452- is simple. It is very useful though.

♦ Hose Clamps - Up To 25mm - 3094- or Hose Clamps - Up To
40mm - 3093-
♦ Engine Support - Basic Set - T40091-
♦ Engine Support - Supplement Kit - T40093A-

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Removing
Note


Connecting .
– Remove the engine cover. Refer to ⇒ Rep. Gr. 15 ; Cylinder
– Remove the complete air filter housing. Refer to ⇒ Rep. Gr.
24 ; Air Filter; Air Filter Housing, Removing and Installing .

stalling .

-arrows-.

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Note
♦ Use pliers to remove the lock washer from the cable bracket.
Do not use a sharp-edged lever. Otherwise the selector lever
cable could get damaged.
♦ Remove the cable bracket -2- from the transmission, if nec‐
essary. Remove the bolts -1- and the lock washer -3-.
♦ Replace the bolts -1- and the lock washers.
♦ Bolt tightening specification -1- 20 Nm +90°.
Caution
Risk of damaging the selector lever cable.

♦ Remove the selector level cable from the cable bracket
when lowering transmission.

Note

warm.
– Clamp the coolant hoses with Hose Clamps - Up To 25mm -

3094- or Hose Clamps - Up To 40mm - 3093- and remove the
hoses from the transmission fluid cooler.
– Seal off the transmission fluid cooler connections with sealing
plugs taken from for example the Engine Bung Set -
VAS6122- .

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Remove the »lower« bolt first.
Caution


them up.
mission.

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One bolt is located inside the hole for the starter -arrow-. Use
Socket - Xzn 14 - T10061- to remove the bolt.
– Remove the plenum chamber cover. Refer to ⇒ Body Exterior;

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– Remove the bolts -arrows- for the left and right lock carrier
retaining brackets.
– Remove the lower mounts on the Engine Support Bridge - En‐

gine Support 28 - 10-222A/28- and replace them with the
Engine Support Bridge - Engine Support 28-2 - 10-222A/
28-2- .
– Remove the bolts -arrows- for securing the engine support
bridge on the lock carrier from the Engine Support Bridge -
Engine Support 28-2 - 10-222A/28-2- .
• Use the bolts present in the Engine Support Bridge - Engine
Support 28-2 - 10-222A/28-2- for attaching the Engine Support
Bridge - Engine Support 28 - 10-222A/28- . Not the bolts for
the retaining bracket.
– Install the Engine Support Bridge - Engine Support 28 -

10-222A/28- and tighten the bolts to 8 Nm -arrows-.
Caution
A second technician is needed to mount the Engine Support

Bridge - 10-222A- on the vehicle to prevent the Engine Support
Bridge - 10-222A- from tipping.
Install the Engine Support Bridge - 10-222A- as shown.

– First slide the Moveable Joints -2- onto the Square Pipe from
the Engine Support Bridge - 10-222A- .
– Mount the Engine Support Bridge - 10-222A- on the suspen‐
sion strut towers and have a second technician hold it to
prevent it from tipping.
– Push the Engine Support - Basic Set - Square Pipe -
T40091/1- - 5- from the front left and right through the Engine
Support Bridge - Engine Support 28 - 10-222A/28- - 6- and
place on each side of the Engine Support - Supplement Kit -
Movable Joint - T40093/4- - 4-.
– Push the Engine Support - Basic Set - Rail with Holes -
T40091/2- - 7- with the Engine Support - Supplement Kit -

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Mount - T40093/5- - 8- in the Engine Support - Supplement Kit

- Movable Joint - T40093/4- - 4-.
– Install the locking pins into the Engine Support - Basic Set -
Rail with Holes - T40091/2- -7- and secure it with the cotter
pins.

10-222A/31-2-
- Moveable Joint - T40091/3-
10-222A/31-1-
ment Kit - Movable Joint -
T40093/4-
- Square Pipe - T40091/1-
gine Support 28 - 10-222A/28-
with Engine Support Bridge -
Engine Support 28-2 -
10-222A/28-2-
- Rail with Holes - T40091/2-
ment Kit - Mount 5 - T40093/5-
9 - Engine Support Bridge -
Spindle - 10-222A/11-
❑ Engaged in the engine
lifting eye -arrow-.
– Tighten all the threaded connections on the Engine Support

Bridge hand-tight. While doing so, adjust the height of the En‐
gine Support Bridge parallel over the Engine Support Bridge -
Engine Support 28 - 10-222A/28- .
– Lightly preload the engine/transmission assembly using the
spindle, but do not lift it.
height.
– Remove the left front housing liner. Refer to ⇒ Body Exterior;
Housing Liner .

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Caution

– Separate the exhaust system at the clamping sleeve and re‐

move the bracket from the subframe -arrows-. Refer to ⇒ Rep.
Gr. 26 .
– Remove the bolts -11- and then remove the pendulum support
– Secure the subframe before removing. Refer to ⇒ Suspen‐

sion, Wheels, Steering; Rep. Gr. 40 ; Subframe; Subframe,
Securing .
Note

formed later.


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– Remove the heat shield above the right drive axle -arrows-.


this cover plate -A-, if equipped.

-A-.
Support Bridge - 10-222A- spindle so that the transmission

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VAS6931- .
– Align the arms of the Transmission Support so that they match
up with the holes in the Transmission Support - Mounting Plate
42A - 3282/42A- .
vehicle.
the transmission.
transmission.
shown.
Note

-arrow-.

Note

Refer to
⇒ “7.4 Transmission, Installing, Jetta MY 11, 2.0L 147 kW Gaso‐
line Engine”, page 127 .

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7.4 Transmission, Installing, Jetta MY 11,

2.0L 147 kW Gasoline Engine
Note
♦ Refer to “Transmission, Removing”

⇒ “7.3 Transmission, Removing, Jetta MY 11, 2.0L 147 kW
Gasoline Engine”, page 115 for a list of the special tools nee‐
ded.
♦ Install the engine/transmission mount without tension. Refer
to ⇒ Rep. Gr. 10 .

Note


lightly lubricated.
as possible.
another all around.

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the bolts -1-.
mount completely.
Caution


Rep. Gr. 10 ; Subframe Mount .
– Tighten the bolts -2- to the tightening specification. Refer to
WARNING



-C-.
– Install the heat shield over the right drive axle. Refer to ⇒
Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles,
Overview and Servicing; Drive Axle Heat Shield .

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Gr. 19 .
– Assemble the exhaust system and attach the exhaust system
bracket to the subframe. Refer to ⇒ Rep. Gr. 26 .
– Install the plenum chamber cover. Refer to ⇒ Body Exterior;
– Install the bolts -arrows- for the left and right lock carrier re‐
taining brackets to the tightening specification. Refer to ⇒
Body Exterior; Rep. Gr. 50 ; Lock Carrier; Lock Carrier - At‐
tachments .
stalling .
– Install the air filter. Refer to ⇒ Rep. Gr. 24 ; Air Filter; Air Filter
– Install the engine cover. Refer to ⇒ Rep. Gr. 15 ; Cylinder
cations .
7.5 Tightening Specifications

Engine: 2.0L TDI; 2.0L TFSI
Note
The -arrows- point to the alignment sleeves.

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M12 - 80 Nm
❑ When using the Insert
Tool - 18 mm - T10179- :
65 Nm.
M10 - 40 Nm

– Tighten the transmission bracket -A- to the transmission to 40
Nm + 90° using the bolts -1-.
– Tighten the bolts -2- to 60 Nm + 90°.
Note
Pry the transmission bracket into the correct seat using a screw‐
driver while tightening the bolts -2-.

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8 Transmission, Transporting and Se‐

curing to Assembly Stand
Always secure heavy parts when transporting.
Remember there is fluid in the transmission. Do not turn the
transmission with the vents facing downward when transporting
or when it is on the assembly stand. The fluid will leak out.
Note
Remove the bleeder caps if necessary and use oil-tight plugs.
Transmission, Transporting
– Use appropriate lifting tools, for example part of Engine Sling
- 2024A- and the Engine/Gearbox Support Shackle - 10-222A/
12- (not illustrated).
The transmission can also be lifted using the Transmission Sup‐

port Jig - 3336- .
Example: Secure the Transmission on the Assembly Stand.
8. Transmission, Transporting and Securing to Assembly Stand 131

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9 Transmission Fluid and Transmis‐

sion Fluid Filter
⇒ “9.1 Transmission Fluid Filter, Replacing”, page 132
⇒ “9.2 Fluid Level, Checking and Filling”, page 133
⇒ “9.3 Fluid, Draining and Filling”, page 136
Pay attention to the general repair information. Refer to
⇒ “1 General Repair Information”, page 1 .
9.1 Transmission Fluid Filter, Replacing
Note
♦ The transmission fluid filter usually does not need to be re‐

placed.
♦ Change the transmission fluid filter “yes or no”. Refer to
page 4 .
Removing
stalling .
– Remove the battery with the battery tray. Refer to ⇒ Rep. Gr.
27 ; Battery; Battery, Removing and Installing .
Note
♦ A little bit of fluid remains inside the transmission fluid filter.

This will drain out once the transmission fluid filter is removed.
♦ Lay some cloths down near the transmission fluid filter before
removing it.

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– Loosen the filter housing -arrow- approximately seven turns.

– Wait 10 seconds.
This allows the fluid to flow from the filter housing back into the
transmission.
– Remove the filter housing and the transmission fluid filter.
Installing
Install in reverse order of removal. Note the following:
– Thoroughly clean any lubricated areas on the transmission.
– Install the transmission fluid filter with the collar -arrow- down‐
ward.
– Install the filter housing and tighten it to 20 Nm.
Further installation is performed in reverse order of the removal.
9.2 Fluid Level, Checking and Filling

Note the following information:
♦ Use the DSG® transmission fluid available as a replacement
part. Refer to the Parts Catalog .
♦ It is necessary to use the Oil Filler - Adapter 6 - VAS6262/6-
on some oil containers.
♦ It may be necessary to shorten the bleed pipe on the Oil Filler
- VAS6262A- . Refer to ⇒ page 134 .
9. Transmission Fluid and Transmission Fluid Filter 133

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Shorten the Bleed Pipe on the Adapter For Oil Filling - VAS6262A-
as Follows:
– Shorten the bleed pipe to dimension -a-. This assures the pipe
on the Adapter For Oil Filling - VAS6262A- will not touch the
bottom on some oil containers.
Dimension -a- = 210 mm
Note
Dimension -a- is measured starting from the shaft (the green sur‐
face) on the Oil Filler - VAS6262A- .
If dimension -a- is greater than 210 mm:
– Make a mark on the bleed pipe, dimension -a-, and cut it, with
for example the Brake Line Tool Kit - Pipe Cutter -
VAS6056/2- .
– Clean the Oil Filler - VAS6262A- .

♦ Vehicle Diagnostic Tester
Requirements
♦ The vehicle is level and all hoist mounts are the same height.
♦ The noise insulation has been removed.
♦ The Vehicle Diagnostic Tester is connected.
♦ To begin working, the oil temperature should not be higher
than 45 °C (113 °F).
♦ Test temperature: 35 ° to 45 °C (95 ° to 113 °F)
Checking
– Connect the Vehicle Diagnostic Tester and identify the vehicle
in Guided Functions .
– Select DSG Transmission .
– Select Check Fluid Level .
Note
Let the transmission cool down if the oil temperature is higher than
45 °C (113 °F).
The engine is idling and the selector lever is in “P”.

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– Move the Used Oil Collection and Extraction Unit -

SMN372500- or a Drip Tray under the transmission near the
transmission drain and check plug.
– Remove the oil drain plug.
It is important to not to interchange the bolts. Remove the bolt
-A- only, near the pendulum support
Transmissions Installed after 09/20/2004, that is, that are »young‐
er« have Only One Bolt -A-.
– Always replace the gasket for the drain plug -arrow-.
Note
Even if the level of transmission fluid is too low, first a small

amount of transmission fluid will flow out of the overflow tube,
because it fills during operation.
– Let the excess fluid drain.

– Install the drain plug with a new gasket as soon as all the fluid
has drained out (it starts to drip).
– If no transmission fluid comes out, then fill.
Filling

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tight.
– Fill 1 liter (1.05 quarts) of transmission fluid.
– Remove the Adapter for Oil Filling - VAS6262A- at the quick-
release coupling and check it.
If Fluid Flows Out of the Adapter Hole
The fluid must not be topped off.
– Let the excess fluid drain.
– As soon as the fluid has run out (it begins to drip), remove the
Oil Filler - VAS6262A- and install the bolt with new gasket.
If No Fluid Flows Out of Hole
– Add another liter. Refer to
WARNING
Too little or too much fluid will impair the transmission.
Install the oil drain plug with new gasket and tighten.
Drain Plug Tightening Specification: 45 Nm
9.3 Fluid, Draining and Filling

Use the DSG® transmission fluid available as a replacement part.
Refer to the Parts Catalog .
Brief Description
Read the fluid temperature first. If it is higher than 50 °C (122 °F),
then let the transmission cool down.
Turn off the engine, remove the overflow pipe and drain any fluid.
Then reinstall the overflow pipe and »overfill« the transmission
with fluid.
Start the engine and drain any excess fluid until the fluid level has
reached the overflow tube.
Requirements
♦ The engine is off.
♦ The vehicle is level and all hoist mounts are the same height.
♦ Noise insulation is removed if necessary
♦ The selector lever is in “P.”
♦ The Vehicle Diagnostic Tester is connected.
♦ To begin working, the fluid temperature should not be higher
than 45 °C (113 °F).

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Procedure
– Follow the rules for clean working conditions when working on
the transmission.
– Only use the DSG® transmission fluid available as a replace‐
ment part. Other oils can cause malfunctions or transmission
failure.
WARNING
Risk of injury due to hot transmission fluid.
– Connect the Vehicle Diagnostic Tester and identify the vehicle

in Guided Functions .
– Select DSG Transmission .
– Select Check Fluid Level .
Note
Let the transmission cool down if the fluid temperature is higher

than 45 °C (113 °F).
WARNING
Do not start the engine if there is no transmission fluid in the

transmission.
– Engine off - do not start!

– Remove the drain plug near the pendulum support -arrow-.
A »black overflow pipe« made out of plastic is located in this hole
(with 8 mm inner hex socket). Its length determines the fluid level
in the transmission.

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– Remove the overflow pipe -arrow- and let the fluid drain.
About 5 liters (5.28 qts) of oil will drain.
– Install the overflow pipe and tighten it to 3 Nm.
tight.

– Fill 5.5 liters (5.8 qts) oil.
– To change containers, close the shut-off valve or hold the Oil
Filler - VAS6262A- higher than the transmission.
– Tighten the drain plug -A- only hand-tight.

– Start the engine.
– Press the brake pedal and select each selector lever position
for approximately three seconds, then move the selector lever
back into »P«.
– Do not turn off the engine.
– Then check the fluid level and fill if necessary. Refer to

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10 Special Tools
Special tools and workshop

equipment required
♦ Transmission Support -
3282-
Mounting Plate 42A -
3282/42A-
Pins 29 - 3282/29-
♦ Torque Wrench 1331
5-50Nm - VAG1331-
40-200Nm - VAG1332-
♦ Engine and Gearbox Jack -
VAS6931-
10. Special Tools 139

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♦ Engine Support Bridge -

10-222A-
♦ Hose Clamps - Up To
25mm - 3094- or Hose
Clamps - Up To 40mm -
3093-
♦ Engine Support - Basic Set
- T40091-
♦ Engine Support - Supple‐
ment Kit - T40093A-
♦ Engine Bung Set -
VAS6122-

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10-222A-
Mounting Plate 42A -
3282/42A-
Engine Support Feet -
10-222A/8-
Engine Support 3 -
10-222A/3-
3282-
♦ Insert Tool - 18mm -
T10179-

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♦ Wrench - Pump/Injector Long Reach - T10054- .
♦ Puller - Crankshaft/Power Steering Seal - T20143-

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♦ Press Piece - Shift Rod/Alternator - VW423-

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35 – Gears, Shafts
1 No Repairs to Gears and Shafts
144 Rep. Gr.35 - Gears, Shafts

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39 – Final Drive, Differential

1 Flange Shaft or Stub Shaft Seals, Re‐
placing
⇒ “1.1 Component Location Overview - Seals”, page 145
⇒ “1.2 Left Flange Shaft Seal, Replacing”, page 146
⇒ “1.3 Right Flange Shaft or Stub Shaft Seal, Replacing”,
page 148
Do not remove both bolts in the right and left flange shafts or the
right stub shaft at the same time. If the differential bevel gears
rotate, it will be difficult to install the bolts.
1.1 Component Location Overview - Seals
Note
Do not remove all the bolts in the left and right flange shafts at the same time. If the differential bevel gears
inside the differential rotate, it will be difficult to install the bolts.
1 - Right Flange Shaft or Stub

Shaft Seal
❑ Replacing. Refer to
⇒ “1.3 Right Flange
Shaft or Stub Shaft
Seal, Replacing”,
page 148 .
2 - Right Flange Shaft
❑ Removing and instal‐
ling. Refer to
⇒ “1.3 Right Flange
Shaft or Stub Shaft
Seal, Replacing”,
page 148 .
3 - Bolt
❑ 30 Nm
4 - Nut
❑ 20 Nm
5 - Selector Lever
6 - Selector Shaft Seal
⇒ “4 Selector Shaft Lev‐
er Gasket, Replacing”,
page 60 .
7 - Left Flange Shaft Seal
⇒ “1.2 Left Flange Shaft
Seal, Replacing”,
page 146 .
1. Flange Shaft or Stub Shaft Seals, Replacing 145

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8 - Left Flange Shaft

❑ Removing and instal‐
ling. Refer to ⇒ “1.2 Left Flange Shaft Seal, Replacing”, page 146 .
9 - Bolt
❑ 30 Nm
1.2 Left Flange Shaft Seal, Replacing

♦ Slide Hammer Set - VW771-
♦ Slide Hammer Set - Hook - VW771/37-
♦ Seal Installer - Flange Shaft - 3305-
♦ Sealing Grease - G 052 128 A1-
♦ Shop Crane - Drip Tray - VAS6208-
Removing
– Press the brake and remove the bolt from the left drive axle
-arrow- (second technician).
Note
After this, the vehicle must not stand on the ground. Refer to ⇒
– Remove the left front wheel.

– Remove the lower section of the left front wheel housing liner.
– Remove the left drive axle. Refer to ⇒ Suspension, Wheels,
Steering; Rep. Gr. 40 ; Drive Axles, Removing and Installing .
– Place the Shop Crane - Drip Tray - VAS6208- or Used Oil
Collection and Extraction Unit - SMN372500- under the trans‐
mission.
146 Rep. Gr.39 - Final Drive, Differential

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– Remove the flange shaft bolt, by installing two bolts into the
flange and counterholding the flange shaft using a tire iron.
– Remove the flange shaft together with the pressure spring.
– Remove the flange seal using the Slide Hammer Set - VW771-
and Slide Hammer Set - Hook - VW771/37- .
Installing
– Lightly oil the new gasket on the outer edge.
– Fill the space on the new seal between the sealing and dust
lip halfway with Sealing Grease - G 052 128- -arrow-.

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– Install the seal all the way in without tilting it.

– Install the flange shaft.
– Tighten the new flange shaft bolt to the tightening specifica‐
tion. Push the flange shaft against the transmission so that the
bolt engages in the thread.
– Install the left drive axle. Refer to ⇒ Suspension, Wheels,
– Install the left wheel. Refer to ⇒ Suspension, Wheels, Steer‐
ing; Rep. Gr. 44 ; Wheel Installation Tightening Specifica‐
tions .
Tightening Specifications
♦ Refer to
⇒ “1.1 Component Location Overview - Seals”, page 145 .
1.3 Right Flange Shaft or Stub Shaft Seal,

Replacing
♦ Seal Installer - Axle Flange - 3158-
Removing
– Remove the right wheel.
– If equipped, remove the drive axle heat shield from the engine
-arrows-.
– Remove the right drive axle. Refer to ⇒ Suspension, Wheels,
Vehicles with an Intermediate Shaft

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– After removing the right drive axle -A-, remove the intermedi‐
ate shaft -B- from the mounting bracket -C- -arrows- and from
the transmission stub shaft.
– Place the Shop Crane - Drip Tray - VAS6208- or Used Oil
Collection and Extraction Unit - SMN372500- under the trans‐
mission.
– Remove the stub shaft bolt -arrow- or the flange shaft.

– Remove the stub shaft or flange shaft together with the pres‐
sure spring.
– Pry out the gasket.
Installing
– Lightly oil the new gasket on the outer edge.
– Fill the space on the new seal between the sealing and dust
lip halfway with Sealing Grease - G 052 128- -arrow-.
– Install the seal all the way in without tilting it.

– Install the stub shaft or flange shaft.
– Tighten the new flange shaft bolt to the tightening specifica‐
tion. Push the stub shaft or flange shaft against the transmis‐
sion so that the bolt engages in the thread.
Vehicles with an Intermediate Shaft
– Replace the O-ring on the stub shaft.
– Grease the splines on the stub shaft.
Note
Refer to the Parts Catalog for the grease allocation.

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– Guide the intermediate shaft -B- through the mounting bracket

-C- and onto the stub shaft.
– Tighten the intermediate shaft on the mounting bracket to the
specification -arrows-. Refer to ⇒ Suspension, Wheels, Steer‐
ing; Rep. Gr. 40 ; Drive Axles, Removing and Installing .
– Install the right drive axle. Refer to ⇒ Suspension, Wheels,
– Install the right wheel. Refer to ⇒ Suspension, Wheels, Steer‐
ing; Rep. Gr. 44 ; Wheel Installation Tightening Specifica‐
tions .
Tightening Specifications
♦ Refer to
⇒ “1.1 Component Location Overview - Seals”, page 145 .

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2 Special Tools
Special tools and workshop

equipment required
♦ Slide Hammer Set -
VW771-
♦ Slide Hammer Set - Hook -
VW771/37-
♦ Seal Installer - Flange Shaft
- 3305-
5-50Nm - VAG1331-
40-200Nm - VAG1332-

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♦ Seal Installer - Axle Flange - 3158-

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3 Revision History
DRUCK NUMBER: MEX5R006621
Fac‐ Edit Job Fee Notes Quality
tory Edi‐ Type dba Checke
Edi‐ tion ck d By
tion
09.2 10/1 Fac‐ N/A Eric P.

015 2/20 tory
15 Up‐
date
05.2 6/17/ Re‐ N/A Jim H
013 2015 for‐
mat
07/2 Lo‐ 102 Eric P
2/20 cal 858
14 Feed 4
back
1/13/ Lo‐ 988 Fix Metta Data for Trans‐ Gary R
2014 cal 140 mission Removing. GWR
Feed
back
08/2 Lo‐ 959 Fixed Metta Data to add Gary R
7/20 cal 001 CPLA and CPPA engines.
13 Feed FB 951624 added text for
back the setting the DSG Trans‐
mission Mechatronic J743
with Vehicle Diagnostic
Tester. GWR
3. Revision History 153

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6-Speed Dual Clutch Transmission 02E

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6-Speed Dual Clutch Transmission 02E

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Service

Service Department. Technical Information

00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

35 - Gears, Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

39 - Final Drive, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

00 – General, Technical Data

1. General Repair Information 1

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

1.3 Brief Overview - Guide

2 Rep. Gr.00 - General, Technical Data

1.4 O-Rings, Gaskets and Seals

1.5 DSG® Transmission Fluid

Be very careful when handling transmission fluid. Dispose of

1.5.1 Fluid Function

1. General Repair Information 3

and minimizes noise. The fluid performs many functions. The

1.5.2 Transmission Fluid Filter, »When To

1.5.3 Fluid and Fluid Level Troubleshooting

1.5.4 Transmission Fluid Drain and Check

4 Rep. Gr.00 - General, Technical Data

1.6 Bolts and Nuts

1.7 Electrical Components

1. General Repair Information 5

2.1 Troubleshooting, General Information

2.2 Transmission “Control Module Malfunc‐

In addition to the highly developed software, much has been done

6 Rep. Gr.00 - General, Technical Data

with too large of a load, accessories installed on the front of

2.3 Fault Finding, Special Information

2.3.1 Transmission Range Display, No “R”

2.3.2 Touch Function Malfunction, Not

2.3.3 »Drive« Faulty - Insufficient Oil Suspec‐

2.3.4 No Faults are Stored

2.3.5 Faults are Stored

2.3.6 Malfunctions »Outside Transmission«

8 Rep. Gr.00 - General, Technical Data

GKF - Transmission Code

On some transmissions, additional code letters are applied on top

3.1 Transmission Code, Reading

One is on top of the transmission near the selector lever cable

To read the transmission code letters under the transmission

– Remove the battery and the battery tray -arrows-. Refer to ⇒

10 Rep. Gr.00 - General, Technical Data

– Remove the bolts -1 and 2- from the transmission bracket

– Attach the transmission bracket -A- to the transmission using

4 Engine Codes - Engine Allocation

12 Rep. Gr.00 - General, Technical Data

14 Rep. Gr.00 - General, Technical Data

The term »clutch« is not completely accurate on closer examina‐

1. Overview - Dual Clutch 15

1 - Dual Clutch with Circlip

Individual Components of Disassembled Dual Clutch

16 Rep. Gr.30 - Clutch

1 - DSG® Clutch/Clutch Hous‐

4 - Outer Clutch Plate

1. Overview - Dual Clutch 17

2 Dual Clutch, Removing and Installing

2.1 Remove Clutch End Cover

– Drain the fluid.

Approximately 5 liters (5.28 qts) of transmission fluid will flow out.