Direct Shift Gearbox 0d9 Eng

Service
Repair Manual
Golf 2015 ➤
Golf Variant 2015 ➤
Direct Shift Gearbox
Edition 09.2015
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - General, Technical Data
30 - Clutch
34 - Controls, Housing
35 - Gears and Shafts
39 - Final Drive, Differential
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Golf 2015 ➤ , Golf Variant 2015 ➤
Direct Shift Gearbox - Edition 09.2015
Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Transmission Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 General Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Start/Stop System Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Safety Precautions when Tow Starting and Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4 Safety Precautions during Road Test with Testing Equipment . . . . . . . . . . . . . . . . . . . . . . 4
3 Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Seals, Sealing Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Bolts and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1 Transmission/Engine Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.3 Gear Ratio Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.1 Component Location Overview - Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1 Overview - Dual Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 Clutch End Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3 DSG® Clutch, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.4 DSG® Clutch, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
34 - Controls, Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1 Mechatronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.1 Overview - Mechatronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.2 Mechatronic, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2 Selector Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.1 Overview - Selector Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.2 Emergency Release from P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.3 Selector Lever Handle, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.4 Button in Handle, Moving Into Installation Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.5 Selector Mechanism, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.6 Selector Lever Cable, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.7 Gearshift Mechanism, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.8 Selector Lever Cable, Checking and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.9 Selector Shaft Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3 Transmission, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.1 Transmission, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.2 Transmission, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3.3 Transmission Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4 Subframe Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
4.1 Overview - Subframe Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5 Transmission, Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Contents i
6 Transmission, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

6.1 Overview - Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
7 Securing on Engine and Transmission Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
8 Transmission Fluid Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
8.1 Transmission Fluid Cooler, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
8.2 Transmission Fluid Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
8.3 Transmission Fluid Filter, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
9 Transmission Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
9.1 Transmission Fluid Level, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
9.2 Transmission Fluid, Draining and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
10 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
35 - Gears and Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

1 Gears and Shafts, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
39 - Final Drive, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

1 Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1.1 Component Location Overview - Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1.2 Left Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1.3 Right Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
3 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
ii Contents
00 – General, Technical Data

1 Identification
(Edition 09.2015)
⇒ “1.1 Transmission Identification”, page 1 .
1.1 Transmission Identification

Example -arrow-:
GKF - Transmission Code

10.05.2 - 05/10/2002
14 - Plant Code
14 15 - Time
001 - Serial Number
1. Identification 1
Reading the Transmission Code on the Transmission Installed

To read the transmission code letters under the console directly
from the transmission, the engine and transmission must be sup‐
ported. 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. Do
not lower farther otherwise the pendulum support will be dam‐
aged. Transmission Bracket, Removing and Installing. Refer to
⇒ “3 Transmission, Removing and Installing”, page 72 .
Note
♦ Additionally the transmission code it on top of the transmission

near the selector lever cable -arrows-.
♦ The transmission code is also listed in the vehicle data plates.
2 Rep. Gr.00 - General, Technical Data

2 Safety Precautions
⇒ “2.1 General Safety Precautions”, page 3 .
⇒ “2.2 Start/Stop System Safety Precautions”, page 3 .
⇒ “2.3 Safety Precautions when Tow Starting and Towing”, page
4.
⇒ “2.4 Safety Precautions during Road Test with Testing Equip‐
ment”, page 4 .
2.1 General Safety Precautions

Observe the following to Avoid Personal Injury and Vehicle Dam‐
age:
WARNING
There is a risk of injury and accident from accidentally engag‐

ing a gear when the engine is running.
♦ Move the selector lever into “P” and set the parking brake
before working on a running engine.
To Prevent Personal Injury and Damage to Electrical and Elec‐

tronic Components, Observe the Following:
♦ Connect and disconnect test equipment only when the ignition
is off.
Caution
Risk of damaging electronic components when disconnecting

the battery.
♦ Complete the steps for disconnecting the battery.
♦ Always turn off the ignition before disconnecting the bat‐
tery.
– Disconnect the battery. Refer to ⇒ Electrical Equipment; Rep.

Gr. 27 ; Battery; Battery, Disconnecting and Connecting .
2.2 Start/Stop System Safety Precautions

When Working on Vehicles with Start/Stop, Note the Following:
WARNING
Danger of injury through automatic motor starting with vehicles

with the Start/Stop System.
♦ For vehicles with an activated Start/Stop System (recog‐
nizable from a notification in the instrument cluster), the
motor can be started automatically if needed.
♦ Always make sure the Start/Stop System is disabled when
working on the vehicle (turn off ignition, if needed, turn the
ignition back on).
2. Safety Precautions 3
2.3 Safety Precautions when Tow Starting

and Towing
Caution
Danger of causing damage to the transmission.

♦ When towing the vehicle, the selector lever must be in “N”
and the vehicle must not be towed further than 50 km (31
miles) and not faster than 50 km/h (31 mph).
Note
The engine cannot be tow started, for example, if the battery is

too weak or if the starter is not working.
2.4 Safety Precautions during Road Test

with Testing Equipment
If Testers and Measuring Equipment Must Be Used during a Test
Drive, Follow the Points Below:
WARNING
There is a risk of an accident due to distractions and improperly

secured testing equipment.
The front passenger airbag poses a risk if it deploys during an
accident.
• Operating testing equipment while driving is a distraction.
• Testing equipment that is not secured properly increases
the risk of personal injury.
♦ Always secure testing equipment on the rear seat using a
strap and have a second person in the rear seat operate
it.

3 Repair Information
⇒ “3.1 General Information”, page 5 .
⇒ “3.2 Clean Working Conditions”, page 5 .
⇒ “3.3 General Repair Information”, page 6 .
⇒ “3.4 Seals, Sealing Rings”, page 7 .
⇒ “3.5 Bolts and Nuts”, page 8 .
3.1 General Information

Transmission
♦ The flywheel transfers the engine torque to the double clutch.
The flywheel and the dual clutch are connected via splines.
Together they assume the function of the dual-mass flywheel.
♦ The transmission is built like a 6-gear manual transmission.
The alternating hydraulic actuation of the double clutch per‐
mits operation similar to that of an automatic transmission.
This means the gears are automatically or manually shifted via
the Tiptronic mode. Clutch pedal is not available.
Selector Mechanism
In contrast to the automatic transmission, the selector lever po‐
sition is no longer transmitted mechanically to the transmission
via the selector lever cable and Multi-Function Transmission
Range (drive position sensor). Selector lever positions and shifts
are transmitted via a separate control module in the selector
mechanism to the transmission control module via the CAN-Bus.
The shift occurs without a cable. The selector lever cable is me‐
chanically brought into the park brake in the selector lever position
“P”.
Shift Point Changes on Inclines and Declines
An additional gear change map automatically selects the gear
changes for gradients dependent upon accelerator pedal position
and driving speed.
• The gear change map for extreme uphill stretches is matched
to engine output
• The gear change map for extreme downhill stretches is match‐
ed to the braking effect of the engine.
• Direct gear selection by way of the Tiptronic function permits
utilization of engine braking action with a specific gear engag‐
ed, for example, on a downhill gradient with a trailer.
3.2 Clean Working Conditions

♦ Always clean the connection points and the area around them
first, and then loosen them.
♦ Seal all open lines and connections immediately with clean
plugs or caps from the Engine Bung Set - VAS6122- .
♦ Place removed parts on a clean surface and cover them so
that they do not get dirty. Use foil and paper. Use a lint-free
cloth.
♦ Always make sure that no dirt enters an “open” transmission.
♦ Only install clean components. Install replacement parts im‐
mediately after removing them from their packaging.
♦ Cover all opened components carefully if it necessary to per‐
form a repair.
3. Repair Information 5
♦ Protect the disconnected connectors from dirt and moisture

and only connect when they are dry.
3.3 General Repair Information

Carefulness, cleanliness and the correct tools are required for
transmission repairs to be successful. The usual basic safety pre‐
cautions also, naturally apply when carrying out vehicle repairs.
A number of generally applicable instructions for individual repair
operations, which are otherwise mentioned at various points in
the Workshop Manual, are summarized here. They apply to this
repair manual.
Guided Fault Finding, On Board Diagnostics (OBD) and Test In‐
struments
♦ Before starting any repairs on the transmission, determine the
cause of the damage as accurately as possible. Refer to Ve‐
hicle Diagnostic Tester , Guided Fault Finding , OBD or
Test Instruments .
Special Tools and Equipment

For a complete list of special tools used in the Repair Manual.
Refer to Equipment and Special Tools.
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 transmission fluid pump are »open«.
♦ 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.
♦ Always clean the connection points and the area around them
first, and then loosen them.
♦ When installing transmission, make sure centering sleeves
are correctly seated between engine and transmission.
Circlips
♦ Do not overstretch the circlips.
♦ Replace damaged or stretched circlips.
♦ The circlips must fit completely inside the groove.
Transmission Fluid, Environmental and Disposal Regulations.
The quality of transmission fluid is crucial to transmission function.
♦ Shake the fluid containers before opening.
♦ Do not mix any additives in the oil. Do not fill with a different
transmission fluid.
♦ The drained transmission fluid must not be used again.
♦ Dispose of drained transmission fluid correctly.
♦ Follow the legal environmental and disposal regulations.
♦ Observe the information on oil the packaging.

Fluid Drain and Check Plug

A plastic overflow tube is located behind this screw -arrow- (with
8 mm hex socket head). Its length determines the oil level in the
transmission.
Electrical Components
Due to an electrostatic charge to the human body, a person can
receive an electrostatic shock when metal objects are touched.
This charge can damage the electrical/electronic components on
the transmission and the selector mechanism.
– Touch a grounded object, such as, a water pipe or a vehicle
hoist, before working on electrical/electronic components. Do
not touch connector or »open« electronic components directly.
3.4 Seals, Sealing Rings

♦ Replace the O-rings, seals and gaskets.
♦ After removing seal rings and seals, always inspect the con‐
tact surfaces at housing or shaft for burrs resulting from re‐
moval, or for other signs of damage.
♦ Before installing the seal rings, lightly oil the outer circumfer‐
ence and fill the space between the sealing lips -arrow- half‐
way with Grease - G 052 128 A1- .
♦ The open side of the seals point toward the fluid to be sealed
in.
♦ Use DSG® transmission fluid only. Other lubricants cause
malfunctions.
♦ Coat the O-rings with DSG® transmission fluid before inserting
to prevent crushing rings during installation.
♦ After replacing the seals, O-rings and sealing rings, check the
transmission fluid level and fill if necessary. Refer to
⇒ “9.1 Transmission Fluid Level, Checking”, page 113 .
3. Repair Information 7
3.5 Bolts and Nuts

♦ Loosen or tighten bolts and nuts on the covers or housings
diagonally.
♦ The tightening specifications stated apply to non-oiled nuts
and bolts.
♦ Use a wire brush to clean the threads of bolts that were
screwed in with locking compound. Install the bolts with Lock‐
ing Fluid - AMV 185 101 A1- .
♦ Use a thread cutter to clean all threaded holes containing self-
locking bolts to remove any locking compound residue. Oth‐
erwise the bolts could shear the next time they are removed.
♦ Please make sure that the thread pitch is correct so that the
proper thread cutter is used during cleaning, and the thread
does not get damaged.
♦ Always replace self-locking nuts and bolts.

4 Technical Data
⇒ “4.1 Transmission/Engine Allocation”, page 9
⇒ “4.2 Capacities”, page 9
⇒ “4.3 Gear Ratio Calculation”, page 10
4.1 Transmission/Engine Allocation

Always use refer to the transmission code letters if a repair re‐
quires original parts.
S tronic Transmission 0D9, Gasoline engines
Transmission Codes PUL, PZQ, QML, RVS PUL, PZQ, QMQ,
QMQ, QSJ, QSQ, QSJ, RVS
RHN, RVS, RVW
Engine 2.0L - 162 kW TFSI 2.0L - 169 kW TFSI 2.0L - 155 kW TFSI
Refer to the Parts Catalog for the following information.
♦ Production time period.
♦ The individual gear ratios
♦ Flange shaft allocation
Always use refer to the transmission code letters if a repair re‐

quires original parts.
S tronic Transmission 0D9, Diesel engines
Transmission Codes PZN, PUG, QMM,
QSD
Engine 2.0L - 110 kW TDI
Common Rail
Refer to the Parts Catalog for the following information.
♦ Production time period.
♦ The individual gear ratios
♦ Flange shaft allocation
4.2 Capacities
Capacities DSG transmission 0D9
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
Change Interval Refer to the ⇒ Maintenance tables .
Grease DSG transmission fluid. Refer to the Parts Catalog.
Transmission fluid is obtainable as a replacement part. Refer to
the Parts Catalog for the part number.
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4. Technical Data 9
4.3 Gear Ratio Calculation

Example:
6th Gear Final Drive
Drive gear ZG1 = 45 ZA1 = 21
Driven gear ZG2 = 28 ZA2 = 70
i = Z2 : Z1 (Z1 = number of teeth on the drive gear, Z2 = number

of teeth on the driven gear)
iG = gear ratio = ZG2 : ZG1 = 28 : 45 = 0.622
iA = axle ratio = ZA2 : ZA1 = 70 : 21 = 3.333
itotal = total ratio = iG x iA = 0.622 x 3.333 = 2.073

5 Electrical Components
5.1 Component Location Overview - Electrical Components
1 - DSG Transmission Mecha‐

tronic - J743-
❑ Installed behind the
transmission cover
❑ Removing and Instal‐
ling. Refer to
⇒ “1.2 Mechatronic, Re‐
moving and Installing”,
page 30 .
2 - Selector Lever - E313-
❑ With Selector Lever
Sensor System Control
Module - J587- , Shift
Lock Solenoid - N110-
and Selector Lever Park
Position Lock Switch -
F319- .
❑ The components are in‐
tegrated in the circuit
board for the shift mech‐
anism function unit and
cannot be replaced indi‐
vidually.
❑ Checking. Refer to the
Vehicle Diagnostic
Tester .
❑ Gearshift mechanism,
removing and installing.
Refer to
⇒ “2.5 Selector Mecha‐
nism, Removing and In‐
stalling”, page 55
3 - Transmission
5. Electrical Components 11
6 Special Tools
Special tools and workshop equipment required
♦ Not Illustrated:
♦ Engine Support Bridge - 10-222A-

30 – Clutch
1 Clutch
⇒ “1.1 Overview - Dual Clutch”, page 13
⇒ “1.2 Clutch End Cover, Removing and Installing”, page 15
⇒ “1.3 DSG® Clutch, Removing”, page 19
⇒ “1.4 DSG® Clutch, Installing”, page 21
1.1 Overview - Dual Clutch

Short Description
♦ The clutch contains two disc packs. The outer, larger disc pack
is called “K 1” (clutch 1). The “K 1” shifts reverse gear and “1st”,
“3rd” and “5th” gears. The inner, smaller “K 2” (clutch 2) shifts
the gears “2”, “4” and “6”.
♦ Assembling the DSG® clutch requires special care, because
all of the components were balanced to each other at the
manufacturer. When positioning components during installa‐
tion, do no rotate them from their original position, otherwise
imbalances will occur, reducing the shift comfort and the life
span.
Replacement Part Package
1. Clutch 13
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 clutch plates in
the dual clutch can slip
out of place. The dual
clutch may not be cor‐
rectly set during installa‐
tion under certain circum‐
stances.
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 24
3 - Clutch End Cover
4 - Circlip
❑ For clutch end cover
Individual Parts of the Disassembled DSG® Clutch
Caution
14 Rep. Gr.30 - Clutch

1 - DSG® Clutch/Clutch Hous‐

ing
❑ Outer clutch pack carri‐
er
2 - Seals
❑ Quantity: 4
3 - Inner Clutch Pack Carrier
❑ Do not remove
Caution
Do not lift or remove the
inner clutch pack carrier,
under any circumstan‐
ces. The clutch discs
could rotate themselves.
4 - Outer Discs
❑ Quantity: 4
5 - Inner Discs
❑ Quantity: 4
6 - Thrust Washer
7 - Circlip
❑ In the event the securing
ring was removed in or‐
der to reinsert discs, it
should be replaced with
a new ring of the same
thickness.
8 - Circlip
❑ After installing a new du‐
al clutch, redetermine
the thickness. Refer to
⇒ page 24 .
9 - Drive Plate
10 - Circlip
❑ Replace after removing
1.2 Clutch End Cover, Removing and Instal‐

ling
♦ Clutch Cover Plate Guide Sleeve - T10302-
Caution
This procedure contains mandatory replaceable parts. Refer

to component overview prior to starting procedure.
Mandatory Replacement Parts

♦ Clutch End Cover
♦ Circlip - Clutch End Cover
1. Clutch 15
Note
Clean the Clutch Cover Plate Guide Sleeve - T10302- before us‐
ing, and do not use any scratched sleeves
Brief Description
The clutch cover seals the transmission toward the outside. It is
held in place by a circlip. Remove the circlip and pry out the clutch
cover. Always replace the clutch cover and the circlip. 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!
To remove and install the clutch end cover, the transmission must
be secured in a vertical position on the assembly stand. Refer to
⇒ “7 Securing on Engine and Transmission Holder”, page 104 .
Removing
– Drain the transmission fluid. Refer to
⇒ “9.2 Transmission Fluid, Draining and Filling”, page 116 .
– Remove the transmission. Refer to
⇒ “3.1 Transmission, Removing”, page 72 .
– Secure the transmission on the assembly stand. Refer to
⇒ “5 Transmission, Transporting”, page 100 .
– If necessary change the transmission fluid filter. Refer to
⇒ “8.3 Transmission Fluid Filter, Removing and Installing”,
page 110 .
– Pry out and remove the circlip -2- for the clutch cover with a
screwdriver -1- in the direction of -arrow-.

– Lift the clutch cover -2- through the opening in the starter with
a screwdriver -1- or a pry bar in direction of -arrow- and then
remove it.
Note
The clutch end cover that was removed cannot be installed again.
Installing
Caution
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. Leaks will develop.
– Only hold the clutch end cover as shown in this illustration!

Note the Following Before Installing the Clutch End Cover:
The new clutch cover must not have any oil in the around the
center seal and it must be dry.
– If necessary, clean the sealing surface on the drive plate

-arrow- thoroughly.
Do not apply adhesive to inside of clutch end cover.
– Carefully remove the adhesive if it has already been applied!
Only coat outer edge of seal with oil.
1. Clutch 17
– Clean the Clutch Cover Plate Guide Sleeve - T10302- “before

using, do not use any scratched sleeves”
– Place the sleeve on a level surface.
The center seal on the new clutch end cover must now be “per‐
formed”:
– Guide the clutch end cover horizontally and evenly over the
whole sleeve in direction of -arrow-. This brings the sealing lip
into its installed position.
– Remove the sleeve upward out of the clutch end cover and
place it on the end of the dual clutch shaft.
– Guide the cover horizontally over the sleeve and press it even‐
ly onto its seat.
Caution
The clutch end cover may not be exposed to direct hammer

hits. If the cover is hit in any way, leakage will definitely occur.
The cover can be pried out of its seat using a screwdriver to install
the “new” circlip -arrow-.
– Install the new circlip.

– Only remove bushing once circlip is installed.

– Install the transmission. Refer to
⇒ “3.2 Transmission, Installing”, page 91 .
– Fill with transmission fluid. Refer to
⇒ “9.2 Transmission Fluid, Draining and Filling”, page 116 .
WARNING
Do not start the engine if there is no transmission fluid in the

transmission.
– After installing the transmission, perform the Basic Set-

ting using the Guided Functions . Refer to Vehicle Diag‐
nostic Tester .
1.3 DSG® Clutch, Removing

Brief Description
• Adjust the dual clutch axial play when installing.
• Secure the transmission to the assembly stand so that it is
vertical when removing and installing the dual clutch. Refer to
⇒ “7 Securing on Engine and Transmission Holder”,
page 104 . This is the only position in which the dual clutch
axial play can later be adjusted without error.
• The large plate carrier is inserted in all clutch plates in the dual
clutch. The large plate carrier must not slide out of the lowest
plate.
• Transmission fluid pump shaft is removed.
• Do not install any wavy circlips
Removing
– Remove the clutch end cover. Refer to
⇒ “1.2 Clutch End Cover, Removing and Installing”, page 15 .
Caution
A »used« clutch must not be installed again.

Removed circlips are also not installed again.
1. Clutch 19
– Remove the circlip -2- from the drive plate with a screwdriver
-1- in direction of -arrow- and dispose of it.
Important! Installed 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 pack
carrier.
If no marking is available:
– Mark the location of the tab to the outer clutch pack carrier
circumference with a waterproof marker as shown in the illus‐
tration.
• When installing, the drive plate tab must be placed back on
this marked location.
– Remove the drive plate in the direction of -arrows-.

– Remove the circlip -arrow- and dispose of it.
Note
This circlip must be replaced and re-measured during installation.
Caution
Carefully remove the DSG® clutch. Make sure that no other

parts of the clutch fall out; for this reason, never turn over the
clutch!
– Remove the DSG® clutch.
– Remove the pump shaft -A-.

– The pump shaft is inserted after installing the new dual clutch.
Lay the shaft down until then.
– Install the dual clutch. Refer to
⇒ “1.4 DSG® Clutch, Installing”, page 21 .
1.4 DSG® Clutch, Installing

♦ Clutch Retaining Bar - T10303-
♦ Dial Gauge Holder - VW387-
♦ Dial Gauge - 0-10mm - VAS6079-
Caution


♦ Circlip - DSG® Clutch and Circlip
♦ Circlip
1. Clutch 21
Caution
♦ The drive plate of a new clutch is not secured with the

circlip, it only sits “taut” in the clutch.
♦ Thus, press the drive plate into the outer clutch pack car‐
rier with both thumbs during the following steps.
♦ The drive plate must be engaged between the teeth of the
exterior clutch pack.
♦ If the drive plate is loosened, the clutch discs in the
DSG® clutch can slip out of place and the DSG® clutch
may not be correctly set during installation under certain
circumstances.
Installing
Caution
A »used« clutch must not be installed again.
– Take the DSG® clutch out of the packaging by pressing the

drive plate into the outer clutch pack carrier with both thumbs.
– Check the bottom side of the multi-plate clutch to see if the 4

hub sealing rings 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.

Important! Installed 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 pack
carrier.
If no marking is available:
– Mark the location of the tab to the outer clutch pack carrier
circumference with a waterproof marker as shown in the illus‐
tration.
• When installing, the drive plate tab must be placed back on
this marked location.
– Insert the Clutch Retaining Bar - T10303- in the positions on

the clutch cover as shown in the illustration.
– Set the DSG® clutch using rotating and hub 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 the di‐
rection of -arrows- to install.
• A second technician should hold the Clutch Retaining Bar -

T10303- .
Note
♦ The bolt remains installed until clutch end plate is installed.

♦ The DSG® clutch must not be turned any more now, otherwise
the Clutch Retaining Bar - T10303- could be twisted in its po‐
sition.
1. Clutch 23
– Remove the drive plate from the installed clutch in the direction
of -arrows-, if necessary, use a screwdriver to carefully pry it
out of the teeth of the outer clutch pack carrier.
– Move the drive plate to the side.
Caution
Do not remove or lift the inner clutch pack carrier, under any
circumstances. The clutch discs could rotate themselves.
Identify the Circlip for the DSG® Clutch

– Select the 2 mm thick ring from the circlips delivered and install
it -arrow-.
Note
This circlip is temporary installed for the measurement of the axial

play.
First Measurement:
• The Clutch Retaining Bar - T10303- remains installed.
– Install the Dial Gauge Holder - VW387- on the transmission
flange.
– Place the -dial gauge button- on input shaft.

– Adjust the -dial gauge- pretension to “0”.
– 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 gauge button

-on the hub of the large clutch pack carrier-.
• The tip of the dial may not be placed on the circlip.
– Adjust the -dial gauge- pretension again to »0«.
– Raise the 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:
The new circlip will be determined according to the following for‐
mula:
2nd Measured value – 1st Measured value + 1.85 mm = thick‐
ness of circlip to be installed
– Write down the result.
The remaining nine circlips are staggered in 0.1 mm increments.
– Measure all the circlips and determine the one that is the
closes match to the result
Determined Measurement for New Circlip
the New Circlip
2.27 mm 2.3 mm
2.24 mm 2.2 mm
– Remove the 2 mm circlip and replace it with the circlip that was
measured.
– Dispose of all other rings remaining and the 2 millimeter thick
ring.
Note
Circlips must only be installed one time.
– Insert the pump shaft.
Note
The pump shaft must be slightly lifted and rotated in direction of

-arrow- in order for it to completely slide into the splines.
1. Clutch 25
– Insert the drive plate into the DSG® clutch.

• The protruding tab of the drive plate must be positioned be‐
tween the color-marked teeth of the outer clutch pack carrier.
Make note of markings that have been changed retrospec‐
tively.
Caution
Only the circlip removed beforehand from the »new« clutch

may be installed. Never install a »used« circlip.
– Install the “new” drive plate circlip.

• The circlip must be installed so that the tab of the drive plate
-arrow- 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.
– Now remove the Clutch Retaining Bar - T10303- between the
DSG® clutch and the housing.
– Install the clutch end cover. Refer to
⇒ “1.2 Clutch End Cover, Removing and Installing”, page 15 .

2 Special Tools
♦ Clutch Cover Plate Guide Sleeve - T10302-
♦ Clutch Retaining Bar - T10303-
♦ Dial Gauge - 0-10mm - VAS6079-
♦ Dial Gauge Holder - VW387-
2. Special Tools 27
34 – Controls, Housing
1 Mechatronic
⇒ “1.1 Overview - Mechatronic”, page 28
⇒ “1.2 Mechatronic, Removing and Installing”, page 30
1.1 Overview - Mechatronic
1 - Transmission Fluid Drain

and Check Plug
❑ 45 Nm
❑ There is an overflow
pipe with a 8 mm inner
hex behind this bolt
-item 3-
⇒ Item 3 (page 28)
❑ Drain the transmission
fluid via the drain- and
check plug and re‐
moved overflow pipe
2 - Seal
3 - Overflow Pipe
❑ 3 Nm
❑ Plastic
❑ To drain the transmis‐
sion fluid, remove the
drain and check plugs.
Refer to -item 1-
⇒ Item 1 (page 28) , and
remove the overflow
pipe.
❑ The length of the over‐
flow pipe determines the
fluid level inside the
transmission
❑ Allocate according to
the Parts Catalog.
4 - Bolt
❑ Quantity: 10
❑ Tightening specification
and sequence. Refer to
⇒ Fig. ““Tightening Specification and Sequence for DSG Transmission Mechatronic -J743- ”“ ,
page 30
5 - Transmission Cover
❑ Removing and installing. Refer to ⇒ “1.2 Mechatronic, Removing and Installing”, page 30 .
6 - Bolt
❑ Quantity: 5
❑ Tightening specification and sequence. Refer to
⇒ Fig. ““Tightening Specification and Sequence for DSG Transmission Mechatronic -J743- ”“ ,
page 30
28 Rep. Gr.34 - Controls, Housing

7 - Seal
8 - DSG Transmission Mechatronic - J743-
❑ Replace the O-ring after disassembly.
❑ With O-rings on connector
❑ Removing and installing. Refer to ⇒ “1.2 Mechatronic, Removing and Installing”, page 30 .
9 - Bleed Cap
❑ Placed on bleed pipe
10 - Bleed Pipe
❑ Pressed into transmission
11 - Transmission Fluid Pump
❑ Insert with new seal
❑ Removing and installing. Refer to
⇒ “8.2 Transmission Fluid Pump, Removing and Installing”, page 107 .
12 - Transmission Fluid Pump Cover
❑ With seal
13 - Bolt
❑ Quantity: 4
⇒ Fig. ““Tightening Specification and Sequence of the Transmission Fluid Pump Cover -A-.”“ ,
page 30
14 - Bolt
❑ Quantity: 4
❑ Different versions. For the correct allocation. Refer to the Parts Catalog.
❑ There are different bolts for the transmission fluid pump. Refer to ⇒ page 109
15 - Seal
Tightening specification and tightening sequence of the trans‐

mission cover -A-.
– Tighten the bolts -arrows- diagonally in steps to 16 Nm.
1. Mechatronic 29
Tightening Specification and Sequence for DSG Transmission

Mechatronic - J743-
Note
Always replace bolts that were tightened with an additional turn.
– Tighten the bolts in steps in the sequence shown:

Step Bolts Tightening Specification/Additional
Turn
1. -1 to 10- 5 Nm
2. -1 to 10- Tighten 90° further.
Tightening Specification and Sequence of the Transmission Fluid

Pump Cover -A-.
– Tighten the bolts -arrows- diagonally in steps to 8 Nm.
1.2 Mechatronic, Removing and Installing

⇒ “1.2.1 DSG Transmission Mechatronic J743 , Removing and
Installing, Transmission Installed”, page 30 .
⇒ “1.2.2 DSG Transmission Mechatronic J743 , Removing and
Installing, Transmission Removed”, page 39 .
1.2.1 DSG Transmission Mechatronic -

J743- , Removing and Installing, Trans‐
mission Installed
♦ Torque Wrench 5-50Nm - VAG1331-
♦ Used Oil Collection and Extraction Unit - SMN372500-
♦ Oil Filler - VAS6262A-
Caution


♦ Bolts - DSG® Transmission Mechatronic - J743
♦ Bolts - Pendulum Support Bolts to Transmission

♦ Bolts - Transmission Fluid Pan

♦ Bolts - Transmission Fluid Pump Cover
♦ O-rings - DSG® Transmission Mechatronic - J743
♦ Seal - Transmission Fluid Drain and Check Plug
♦ Seal - Transmission Fluid Pan
Note
♦ Follow the guidelines for clean working conditions. Refer to

♦ Pay attention to the general repair information. Refer to
Removing
Always make sure that no dirt enters an “open” transmission.
Dirt entering can cause a transmission malfunction especially with
»open« Direct Shift Gearbox (DSG®) Mechatronic and/or trans‐
mission fluid pump.
The Mechatronic can get stuck on the alignment pins when the
transmission is very warm. Let the transmission cold down.
– Move the selector lever into “P”.
– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.
Gr. 66 ; Noise Insulation; Overview - Noise Insulation .
If present:
– Remove the connecting hose between the charge air cooler
and the charge air pipe. Refer to ⇒ Rep. Gr. 21 ; Overview -
Charge Air System .
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.
♦ Depending on the vehicle, the parts could be:

♦ Fan mount -arrow-
♦ Charge or cold air pipes
Caution
Risk of destroying Mechatronic with static discharge.

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

with hand (without wearing a glove). Refer to ⇒ page 7 .
1. Mechatronic 31
– Release and remove the connector rotary lock -1- for the Me‐
chatronic by turning it in the direction of the starter -A-.
– Remove the wires and bracket from the front of the transmis‐
sion cover -arrows- (two M6 nuts).
– Route the wires near the transmission cover upward and tie
them up.
– Place the Used Oil Collection and Extraction Unit -
SMN372500- under the transmission near the transmission
cover.
Caution
Fluid will leak out of the transmission cover when the bolts are
removed. Risk of injury due to hot transmission fluid.
– Loosen the bolts -arrows- on the transmission cover -A- diag‐

onally and then remove them. Hold down the transmission
cover at the same time.
– Drain the transmission fluid and remove the cover and seal.
Approximately 3 liters (3.1 quarts) of transmission fluid will drain
out.
Note
Always replace the screws on the transmission fluid pan.

page 110 .
– Remove the lower left front wheel housing liner. Refer to ⇒
Body Exterior; Rep. Gr. 66 ; Wheel Housing Liner; Overview
- Front Wheel Housing Liner .
– Remove the bolts -arrows- from the transmission fluid pump

cover and remove the cover -A-.
Note
Always replace the cover and the transmission fluid pump bolts.

– Remove the pendulum support bolts -1- from the transmission.

The transmission can now be “pressed down” slightly to remove
the Mechatronic.
– Touch a grounded object again before touching the Mecha‐
tronic.
– Loosen and remove the bolts -1 through 10- in the specified

sequence.
– Push the transmission rearward and pull the Mechatronic

carefully from the transmission housing until the sensor arm
-B- on the rear is no longer in the transmission housing.
When handling the Mechatronic, be particularly aware of the
“long” sensor arm -B-.
– Carefully move the DSG Transmission Mechatronic - J743-
downward.
Store Mechatronic Properly

1. Mechatronic 33
Caution
Never lift the Mechatronic by the “sensor arm” and never let it
rest on the arm.

If the “arm” is damaged, the Mechatronic must be replaced.

Installing
Touch a grounded object before touching the Mechatronic
⇒ page 7 .
Note
The DSG Transmission Mechatronic - J743- and the transmission

must be the same temperature. Otherwise the alignment pins will
not “clamp” during installation.
– Carefully mount the Mechatronic onto the alignment pins

-arrow-. The goal is for the “sensor arm” to be in its
-installed position-.
1. Mechatronic 35
– Hold the Mechatronic facing up. The sensor arm must not
touch the sensor wheel.
– Make sure the Mechatronic unit is installed correctly.
– Tighten the new bolts -1 through 10- hand-tight.
– Tighten the bolts -1 to 10- in the tightening sequence provided.
Tightening specification. Refer to :
⇒ Fig. ““Tightening Specification and Sequence for DSG
Transmission Mechatronic -J743- ”“ , page 30
– Replace both -O-rings- if the “old” Mechatronic is being instal‐

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

careful not to pinch any wires when doing this.
– Install the new bolts -arrows- and tighten in a diagonal se‐
quence in stages.

– Attach the cable bracket to the transmission cover -arrows- (2

M6 nuts).
– Mount the new transmission fluid pump cover -A-. Tighten the
new bolts -arrows- and tighten in a diagonal sequence in
stages.
– Install the lower left front wheel housing liner. Refer to ⇒ Body
Exterior; Rep. Gr. 66 ; Wheel Housing Liner; Overview - Front
Wheel Housing Liner .
Connect the connector -A- on the DSG Transmission Mechatronic

- J743- as follows:
– The arrow -D- on the DSG Transmission Mechatronic - J743-
-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 direction of -arrow-.
– Install the new bolts -1- for the pendulum support on the trans‐
mission. Refer to ⇒ Rep. Gr. 10 ; Subframe Mount; Overview
- Subframe Mount .
– Install the air filter housing if it was removed earlier. Refer to
⇒ Engine Mechanical, Fuel Injection and Ignition; Rep. Gr.
24 ; Air Filter; Air Filter Housing, Removing and Installing .
– Do not start the engine.
– Move the Used Oil Collection and Extraction Unit -
SNM372500- under the transmission near the transmission
fluid drain and check plug.
1. Mechatronic 37
– Remove the transmission fluid drain- and check plug -arrow-.
– Install the Oil Filler - VAS6262A- into the check hole hand-
tight.
– Shake before opening.

– Attach the Oil Filler - VAS6262A- to the oil bottle. Be sure to
read the instructions. Refer to ⇒ page 113 .
– Fill 3 liters (3.1 quarts) of transmission 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. Refer to
⇒ “9.1 Transmission Fluid Level, Checking”, page 113 . The Oil
Filler - VAS6262A- remains installed.
– Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr.
66 ; Noise Insulation; Overview - Noise Insulation .

– Connect the Vehicle Diagnostic Tester .

– Perform a basic setting on the DSG Transmission Mechatronic
- J743- .
Note
After installing a “new” Mechatronic, readapt the immobilizer.
Tightening Specifications
♦ Refer to ⇒ “1.1 Overview - Mechatronic”, page 28 .
♦ Cable bracket on the transmission cover. Refer to
⇒ “3.3 Transmission Tightening Specifications”, page 96 .
1.2.2 DSG Transmission Mechatronic -

J743- , Removing and Installing, Trans‐
mission Removed
Caution


♦ Bolts - DSG® Transmission Mechatronic - J743
♦ Bolts - Pendulum Support Bolts to Transmission
♦ Bolts - Transmission Fluid Pan
♦ Bolts - Transmission Fluid Pump Cover
♦ O-rings - DSG® Transmission Mechatronic - J743
♦ Seal - Transmission Fluid Drain and Check Plug
♦ Seal - Transmission Fluid Pan
Note
♦ Follow the guidelines for clean working conditions. Refer to

♦ Pay attention to the general repair information. Refer to
Always make sure that no dirt enters an “open” transmission. Dirt

entering can cause a transmission malfunction especially with
“open” Direct Shift Gearbox (DSG®) Mechatronic and/or oil pump.
Removing
SMN372500- or Drip Tray under the transmission.
1. Mechatronic 39
– Remove the Transmission fluid drain- and check plugs

-arrow- and drain the transmission fluid.
A plastic overflow tube is located in this hole (with 8 mm hex
socket head, tightening specification: 3 Nm). Its length deter‐
mines the oil level in the transmission.
– Remove this overflow pipe and drain the rest of the transmis‐
sion fluid.
Note
Approximately 5 liters (5.28 qts) of transmission fluid will drain.

Continue to have the Used Oil Collection and Extraction Unit -
– Install the overflow pipe and tighten.

page 110 .
– Loosen transmission fluid pan bolts -arrows- diagonally and

remove. Remove the transmission fluid pan.
Note
Always replace the screws on the transmission cover.
– Remove the bolts -arrows- from the transmission fluid pump

cover and remove the cover -A-.
Note
Always replace the bolts for the transmission fluid pump cover
and the cover.
– Touch a grounded object again before touching the Mecha‐

tronic.
– Remove the bolts -1 through 10- diagonally. Start with the bolt
-1-.

Replace all 10 -bolts-.

– Remove the Mechatronic.
When handling the Mechatronic, be particularly aware of the
“long” sensor arm.
Store Mechatronic Properly
1. Mechatronic 41
Caution
Never lift the Mechatronic by the “sensor arm” and never let it
rest on the arm.

If the “Arm” is Damaged, the Mechatronic Must Be Replaced.

Installing
– Replace both O-rings -arrows- on the Mechatronic connection

if the “old” Mechatronic is going to be installed again.
A “new” Mechatronic already has “new” rings.
– Coat the O-rings with DSG® transmission fluid.
– Carefully mount the Mechatronic on the alignment pin

-arrow-. The goal is for the “sensor arm” to be in its
-installed position-.
1. Mechatronic 43
– The sensor arm must not touch the sensor wheel.

All of the bolts -1 through 10- must be replaced.

– First install all of the bolts -1 to 10- and tighten them by hand.
– Tighten all of the bolts -1 to 10- in the tightening sequence
provided. Tightening specification. Refer to
⇒ Fig. ““Tightening Specification and Sequence for DSG
Transmission Mechatronic -J743- ”“ , page 30
– Clean the transmission fluid pan gasket and transmission
sealing surfaces.
– 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 the new bolts -arrows- and tighten in a diagonal se‐
quence in stages.
1. Mechatronic 45
– Mount the new transmission fluid pump cover -A-. Tighten the
stages.
After Installing Transmission
– Fill with transmission fluid. Refer to
⇒ “9 Transmission Fluid”, page 113 .
– Connect the Vehicle Diagnostic Tester Vehicle Diagnostic

Tester .
– Perform a basic setting on the DSG Transmission Mechatronic
- J743- .
Note
After installing a “new” Mechatronic, readapt the immobilizer.
♦ Refer to ⇒ “1.1 Overview - Mechatronic”, page 28 .

2 Selector Mechanism
⇒ “2.1 Overview - Selector Mechanism”, page 47
⇒ “2.2 Emergency Release from P”, page 50
⇒ “2.3 Selector Lever Handle, Removing and Installing”,
page 51
⇒ “2.4 Button in Handle, Moving Into Installation Position”,
page 53
⇒ “2.5 Selector Mechanism, Removing and Installing”,
page 55
⇒ “2.6 Selector Lever Cable, Removing and Installing”,
page 63
⇒ “2.7 Gearshift Mechanism, Checking”, page 67
⇒ “2.8 Selector Lever Cable, Checking and Adjusting”,
page 68
⇒ “2.9 Selector Shaft Seal, Replacing”, page 69
2.1 Overview - Selector Mechanism

⇒ “2.1.1 Overview - Selector Mechanism, ZF”, page 47 .
⇒ “2.1.2 Overview - Selector Mechanism, ECS”, page 49 .
2.1.1 Overview - Selector Mechanism, ZF
2. Selector Mechanism 47
1 - Handle with Shift Cover

❑ Do not remove the han‐
dle unnecessarily. For
emergency release, on‐
ly cover must be re‐
moved. Refer to
⇒ “2.2.1 Emergency Re‐
lease from P, ZF”,
page 50 .
❑ Removing and instal‐
ling. Refer to
⇒ “2.3 Selector Lever
Handle, Removing and
Installing”, page 51 .
2 - Selector Mechanism
❑ 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
ling. Refer to
stalling”, page 55 .
3 - Bolt
❑ 8 Nm
❑ Quantity: 4
4 - Plugs
5 - Nut with Collar
❑ 8 Nm
❑ Quantity: 4
6 - Selector Housing
❑ Available only together with the selector mechanism. Refer to the Parts Catalog
7 - Transmission
8 - Bolt
❑ 20 Nm + 90
❑ Quantity: 2
❑ For attaching the cable bracket to the transmission
9 - Lock Washer
10 - Lock Washer
❑ Installed location: the offset side faces forward, toward the front of the vehicle.
11 - Lock Washer
12 - Selector Lever Cable
❑ Do not grease the selector lever cable.

⇒ “2.6.1 Selector Lever Cable, Removing and Installing, ZF”, page 63 .
❑ Checking or adjusting. Refer to ⇒ “2.8 Selector Lever Cable, Checking and Adjusting”, page 68 .
2.1.2 Overview - Selector Mechanism, ECS
1 - Handle with Shift Cover

❑ Do not remove the han‐
dle unnecessarily. For
emergency release, on‐
ly cover must be re‐
moved. Refer to
⇒ “2.2.2 Emergency Re‐
lease from P, ECS”,
page 51 .
ling. Refer to
⇒ “2.3 Selector Lever
Handle, Removing and
Installing”, page 51 .
2 - Bolt
❑ 8 Nm
❑ Quantity: 4
3 - Selector Mechanism
❑ 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
ling. Refer to
stalling”, page 55 .
4 - Selector Lever Cable
❑ Do not grease the selec‐
tor lever cable.
ling. Refer to ⇒ “2.6.2 Selector Lever Cable, Removing and Installing, ECS”, page 65 .
❑ Checking. Refer to ⇒ “2.8 Selector Lever Cable, Checking and Adjusting”, page 68 .
❑ Adjusting. Refer to ⇒ “2.8 Selector Lever Cable, Checking and Adjusting”, page 68 .
5 - Lock Washer
6 - Nut with Collar
❑ 8 Nm
❑ Quantity: 4
7 - Selector Housing
❑ Available only together with the selector mechanism. Refer to the Parts Catalog
8 - Cover
9 - Bolt
❑ 20 Nm + 90
❑ Quantity: 2
❑ For attaching the cable bracket to the transmission
10 - Transmission
11 - Lock Washer
❑ Installed location: the offset side faces forward, toward the front of the vehicle.
12 - Bolt
❑ 13 Nm
❑ Selector lever cable adjusting screw
13 - Lock Washer
2.2 Emergency Release from P

⇒ “2.2.1 Emergency Release from P, ZF”, page 50 .
⇒ “2.2.2 Emergency Release from P, ECS”, page 51 .
2.2.1 Emergency Release from P, ZF

Do Not Remove the Handle
– Press the brake or set the parking brake.
– Open the storage compartment door.
– Grab and under the shift cover by hand and by pulling upward
unclip the cover.

– Hold the shift cover to the side and from above push the yellow
plastic part and hold it in this position.
The selector lever can now be moved out of “P”.
Note
If the selector lever is not moved back into “P”, the solenoid for
the shift block will be automatically locked in the position “P”. The
solenoid must be released again.
2.2.2 Emergency Release from P, ECS

Do Not Remove the Handle
– Press the brake or set the parking brake.
– Grab and under the shift cover by hand and pulling upward
unclip the cover.
– Unclip the shift cover and hold it to the side.
– With a screwdriver push the plastic part on the side from the
right and hold it in this position
The selector lever can now be moved out of “P”.
Note
If the selector lever is not moved back into “P”, the solenoid for
the shift block will be automatically locked in the position “P”. The
solenoid must be released again.
2.3 Selector Lever Handle, Removing and

Installing
♦ Hose Clip Pliers - VAG1275A-
Caution


♦ Clamp - Shift Handle
Short Description:
The handle is removed together with the shift cover.
Removing
– Move the selector lever into “D”.
It is not necessary to pull out the button -arrow- manually. The
push button locks in the installation position by itself when the
handle is removed.
– Grab and under the shift cover by hand and pulling upward
unclip the cover.
– Disconnect the connector.
– Cut the clamp under the boot -arrow- with a side cutter.
– Pull the handle up without pressing the button.
Note
Do not push the button once the handle has been removed oth‐
erwise it will not be possible to remove the handle again.
Installing
Install in reverse order of removal. Note the following:
• The selector lever is in the “D” position.

Note
♦ There is the possibility that the button can be pressed into the
handle. Never install the handle when the button is pressed in.
♦ Move the button in the installation position. Refer to
page 53 .
♦ A new handle is delivered with an assembly fastener. Pull out
the safety catch in direction of -arrow- just before installing the
new handle.
– Install the handle with a new clamp -arrow-. Do not clamp the
clamp yet.
– Press the button after installing it.
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 53 . Install the handle again.
– If the button after being pressed return to its starting position,

the clamp can be clamp off using Hose Clamp Pliers -
VAG1275A- .
– Connect the connector.
– Clip on the cover.
2.4 Button in Handle, Moving Into Installa‐

tion Position
If the button was pushed in by mistake, the installed position can
be set again.
There are two ways to move the button into the installation posi‐
tion, “with” or “without” assembly fastener. The following de‐
scribes both ways.
Moving the Handle “with” an Assembly Fastener into the Instal‐
lation Position:
Make sure the assembly fastener has an eye -arrow- at the front.
Other assembly fasteners cannot be used.
– Press the button and push the assembly fastener (with the
eye) -arrow- all the way in until it latches into place. Then re‐
lease 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:
– Remove the trim -A- from the handle.

– Push the small lever -1- 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 further.

♦ Install the trim back onto the selector mechanism only after the
handle is installed. This way it is possible to see if the small
lever fits into the pull rod when the button is pushed.
2.5 Selector Mechanism, Removing and In‐

stalling
⇒ “2.5.1 Shift Mechanism with Selector Lever Cable, Removing
and Installing”, page 55
⇒ “2.5.2 Gearshift Mechanism without Selector Lever Cable, Re‐
moving and Installing, ZF”, page 57
⇒ “2.5.3 Shift Lever Mechanism without Selector Lever Cable,
Removing and Installing, ECS”, page 60
2.5.1 Shift Mechanism with Selector Lever

Cable, Removing and Installing
Short Description
Remove the center console inside the passenger compartment.
It is necessary to remove the heat shield under the vehicle.
Removing
– Remove the selector lever handle. Refer to
⇒ “2.3 Selector Lever Handle, Removing and Installing”, page
51 .
– Remove the center console. Refer to ⇒ Body Interior; Rep.
Gr. 68 ; Center Console; Center Console, Removing and In‐
stalling .
– Remove the air guide channel from the center console. Refer
to ⇒ Heating, Ventilation and Air Conditioning; Rep. Gr. 87 ;
Air Routing; Overview - Air Routing and Air Distribution in Pas‐
senger Compartment .
– Remove left and right bolts -1- and bracket -2-.
– Disconnect the connector from the selector mechanism to the
vehicle wiring harness.
– Remove the air filter housing:
♦ Gasoline engine. Refer to ⇒ Engine Mechanical, Fuel Injec‐
tion and Ignition; Rep. Gr. 24 ; Air Filter; Air Filter Housing,
Removing and Installing .
♦ Diesel engine. Refer to ⇒ Rep. Gr. 23 ; Air Filter; Air Filter
Housing, Removing and Installing .
Loosen the adjusting screw -arrow-.

– Remove the lock washers -A and B-. The lock washers must
later be replaced when adjusting selector lever cable.
Use pliers to remove the lock washer -B-. Do not use a sharp-
edged lever. Otherwise the selector lever cable could get dam‐
aged.
– Remove the center tunnel heat shield under the gearshift
mechanism. Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Molding/
Trim/Extensions/Trim Panels; Floor Heat Shield, Removing
and Installing .
– Remove the bracket -A-, if equipped.

– Remove the nuts -arrows- in the vehicle interior.
– Remove the selector mechanism -B- with the selector lever
cable and selector housing downward.
Installing
Note
♦ Do not bend or kink the selector lever cable.

♦ Do not lubricate the selector lever cable.
♦ After installation, the selector lever cable movement must be
checked and adjusted.
– Install the heat shield under the gearshift mechanism. Refer

to ⇒ Body Exterior; Rep. Gr. 66 ; Molding/Trim/Extensions/
Trim Panels; Floor Heat Shield, Removing and Installing .

– Install the bracket -2-. Refer to ⇒ Body Interior; Rep. Gr. 68 ;

Center Console; Center Console, Removing and Installing .
– Install the air guide channel from the center console. Refer to
⇒ Heating, Ventilation and Air Conditioning; Rep. Gr. 87 ; Air
Routing; Overview - Air Routing and Air Distribution in Pas‐
– Install the center console. Refer to ⇒ Body Interior; Rep. Gr.
68 ; Center Console; Center Console, Removing and Instal‐
ling .
– Install the selector lever handle. Refer to
51 .
– Adjust the selector lever cable. Refer to
page 68 .
– Check the selector mechanism. Refer to
⇒ “2.7 Gearshift Mechanism, Checking”, page 67 .
– Install the air filter housing:
♦ Selector mechanism to the body. Refer to
⇒ “2.1 Overview - Selector Mechanism”, page 47 .
2.5.2 Gearshift Mechanism without Selector

Lever Cable, Removing and Installing,
ZF
Caution


♦ Lock Washer - Locking Mechanism
Short Description
Removing
51 .
stalling .
– Remove the bracket -2-, to do this remove the left and right
bolts -1-.
– Position the selector lever on the selector mechanism in the
“N” position. The cable can only be loosened in this position.
and Installing .
– Remove the plugs, and remove the lock washer -arrow-.

Always replace the lock washer.
– Insert a large screwdriver into the grooves on the locking

mechanism and turn 90° in the direction of the -arrow-.
– Remove the cable from the selector mechanism.

– Remove the selector mechanism -B- with the gearshift hous‐
ing downward.
Installing
Note

• The selector lever for the gearshift mechanism is in the “N”

position. The cable can only be locked in this position.

– Guide the cable into the selector mechanism in direction of

-arrow- until the locking mechanism -arrow- is visible.
– Turn the locking mechanism 90° in the direction of the

-arrow- with a large screwdriver.
– The cable is correctly locked when the grooves on the locking

mechanism are at a right angle to the cable.
– Install new lock washer -arrow- and replace the plugs.

– Install the heat shield under the shift lever mechanism. Refer


ling .
51 .
page 68 .
2.5.3 Shift Lever Mechanism without Selector

Lever Cable, Removing and Installing,
ECS
Caution


♦ Lock Washer - Selector Housing
♦ Cover - Selector Housing
Short Description
Removing
51 .
stalling .

– Remove the bracket -2-, to do this remove the left and right
bolts -1-.
“N” position.
and Installing .
– Pry up the lower cover from the selector mechanism in the

direction of -arrow- and remove.
Note
Do not reuse the cover. Always replace after removing.
– Release the cable as shown with a screwdriver and remove

from the selector lever in the direction of -arrows-.
– Remove the lock washer in the direction of -arrow-.

– Remove the cable from the selector mechanism.

– Remove the selector mechanism -B- with the gearshift hous‐
ing downward.
Installing
Note

• The selector mechanism selector lever is in the “N” position.

– Guide the cable on the selector mechanism, inset in the se‐
lector lever and install new lock washer.

ling .
51 .
page 68 .

2.6 Selector Lever Cable, Removing and In‐

stalling
⇒ “2.6.1 Selector Lever Cable, Removing and Installing, ZF”,
page 63 .
⇒ “2.6.2 Selector Lever Cable, Removing and Installing, ECS”,
page 65 .
2.6.1 Selector Lever Cable, Removing and In‐

stalling, ZF
Caution


♦ Lock Washers - Selector Lever Cable
Removing
– Remove the air filter housing. Refer to ⇒ Engine Mechanical,
Fuel Injection and Ignition; Rep. Gr. 24 ; Air Filter; Air Filter
Housing, Removing and Installing or ⇒ Rep. Gr. 23 ; Air Filter;
Air Filter Housing, Removing and Installing
aged.
and Installing .
– Remove the plugs, and remove the lock washer -arrow-.

– Insert a large screwdriver into the grooves on the locking

mechanism and turn 90° in the direction of the -arrow-.
– Pull the cable from the selector mechanism and remove.
Installing
Note

♦ After installing check the selector lever cable for ease of move‐
ment.
• The selector lever for the gearshift mechanism is in the “N”

position. The cable can only be locked in this position.
– Guide the cable in the selector mechanism in direction of

-arrow- until the locking mechanism -arrow- is visible.
– Turn the locking mechanism 90° in the direction of the

-arrow- with a large screwdriver.
– The cable is correctly locked when the grooves on the locking

mechanism are at a right angle to the cable.

– Install new lock washer -arrow- and replace the plugs.
– Remove the cable from the transmission and secure using a

new lock washer -B-. Do not install the lock washer -A- yet. It
will be installed after the cable is checked and adjusted.
page 68 .
– Install the air filter housing. Refer to ⇒ Engine Mechanical,
Fuel Injection and Ignition; Rep. Gr. 24 ; Air Filter; Air Filter
Housing, Removing and Installing or ⇒ Rep. Gr. 23 ; Air Filter;
Air Filter Housing, Removing and Installing
2.6.2 Selector Lever Cable, Removing and In‐

stalling, ECS
Caution


♦ Lock Washers - Selector Lever Cable
♦ Cover - Selector Mechanism
Removing

aged.
and Installing .
– Pry up the lower cover from the selector mechanism in the

direction of -arrow- and remove.
Note
Do not reuse the cover. Always replace after removing.
– Release the cable as shown with a screwdriver and remove

from the selector lever in the direction of -arrows-.
– Remove the lock washer in the direction of -arrow-.

– Pull the cable from the selector mechanism and remove.
Installing
Note

• The selector mechanism selector lever is in the “N” position.

– Guide the cable on the selector mechanism, inset in the se‐
lector lever and install new lock washer.

– Remove the cable from the transmission and secure using a

new lock washer -B-. Do not install the lock washer -A- yet. It
will be installed after the cable is checked and adjusted.
page 68 .
2.7 Gearshift Mechanism, Checking

The starter does not work when the selector lever is in “R”, “D”
and “S” or in the tiptronic gate.
Over 5 km/h:
The shift lock solenoid must not block the selector lever when the
lever is in “N”. The selector lever can be moved back into a an‐
other gear.
Below 5 km/h:
The shift lock solenoid will block the selector lever approximately
1 second after the lever is moved into “N”. The selector lever can
be moved out of “N” only 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 locking 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 shift into a gear. Slowly move the selector lever slowly from “P”
through “S”; while doing this, check whether display of selector
lever position in instrument panel insert matches actual selector
lever position.
The Selector Lever is in “N” and the Ignition is Turned On:
• If the brake pedal is not depressed:
The selector lever is locked and cannot be moved out of “N” 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 shift into a gear.
Selector Level in the “Tiptronic” Position
• Move selector lever into Tiptronic gate:
The illuminated “D” in the 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.
Ignition and Lights Switched On
The appropriate symbol is being lit up in shift mechanism cover.
Transmission Range Display
Simultaneous lighting of all segments of transmission range se‐
lector lever display indicates transmission is in emergency run‐
ning mode.
2.8 Selector Lever Cable, Checking and Ad‐

justing
Short Description
The selector lever cable must be disconnected from the trans‐
mission in order to check it for ease of movement. Lay the
removed end down so that it does not touch anything.
Then selector lever is moved and installed again on the trans‐
mission.
After that, selector lever cable must be adjusted.
Do not lubricate the cable connections.
After that, the selector lever cable must be adjusted.
Always Adjust the Selector Lever Cable If:
♦ The selector lever cable was removed from the transmission.
♦ The engine and/or transmission were removed and installed.
♦ Parts of subframe mount were removed and installed.
♦ The cable itself or the selector mechanism was removed and
installed.
♦ Engine/transmission positions changes, for example, were in‐
stalled free of tension.
Checking
– Remove the selector lever cable from the transmission.
– Move the selector lever from “P” through “S” and back to “P”
several times.
• The selector lever must move easily.
– Adjust the selector lever cable.
Adjusting

Gearshift Lever, Moving into “P”

The transmission gearshift lever must be pushed “all the way
back”.
– Pull the transmission gearshift lever forward.
– Push the transmission gearshift lever “to the rear” -arrow-.

“P” is in the Second Detent.
Note
♦ Make sure the transmission is in “P” (parking lock is engaged)

if raising the vehicle. It must not be possible to turn the front
wheels.
♦ The transmission is also in “P” if the vehicle does not move
with wheels spinning freely.
– Install the cable with the loose adjusting screw -arrow- and the
new lock washer -A and B-, if they were removed earlier.
– Tap the handle on the selector lever back and forth gently but
do not move it out of “P” under any circumstances.
– Tighten the adjusting screw -arrow-.
This ends the adjustment.
Component Nm
Selector lever cable adjusting bolt 13
2.9 Selector Shaft Seal, Replacing

Short Description:
The seal can be replaced only when the transmission is removed.
Caution


♦ Nut - Gearshift Lever

♦ Press Piece - Shift Rod/Alternator - VW423-
♦ Puller - Crankshaft/Power Steering Seal - T20143-
♦ Sealing Grease - G 052 128 A1-
– Remove the transmission. Refer to
– Remove the selector lever cable from the transmission. Refer
to
⇒ “2.5 Selector Mechanism, Removing and Installing”,
page 55 .
– Remove nut -arrow- and remove transmission gearshift lever
-A- from the gearshift shaft.
– Pry out the seal in direction of -arrow-.
– Lightly oil the new gasket on the outer edge.

– Fill the space between the sealing and dust lip -arrow- halfway
with Sealing Grease - G 052 128 A1- .

• The closed side of the gasket -arrow- points to the Press Piece
- Shift Rod/Alternator - VW423- .
– Install the new seal all the way. Do not tilt the gasket when
installing it.
– Position the gearshift lever -A- and tighten the new nut
-arrow-.
The Gearshift Lever Only Fits to the Splines in One Position.
– Attach the selector lever cable to the transmission. Refer to
page 68 .
♦ Transmission selector lever to selector shaft. Refer to
⇒ “6.1 Overview - Transmission”, page 101 .
3 Transmission, Removing and Instal‐

ling
3.1 Transmission, Removing

⇒ “3.1.1 Transmission, Removing, Vehicles with Gasoline En‐
gine”, page 72
⇒ “3.1.2 Transmission, Removing, Vehicles with Turbo Diesel
Engine”, page 81
3.1.1 Transmission, Removing, Vehicles with

Gasoline Engine
Brief description
The transmission is removed downward separately.
»From above«:
The battery, air filter and starter are removed. Engine and trans‐
mission are supported before the left subframe mount is removed.
»From underneath«:
The -subframe- is removed together with the
-pendulum support- and -both control arms-. The -steering gear-
remains in the vehicle.
Both driveshafts are disconnected from the transmission and re‐
main inside the wheel bearing housings. Occasionally they will be
moved to the side, but they still remain on the vehicle.

♦ Engine Support Bridge - Gearbox Adapter - 10-222A/29-
♦ Engine Support Bridge - Engine Support 18 - 10-222A/18-
♦ Engine/Gearbox Support Shackle (2 pc.) - 10-222A/12- (quan‐
tity 2)
♦ Transmission Support - Pins 29 - 3282/29-
♦ Transmission Support - 3282-
♦ Engine and Gearbox Jack - VAS6931-
♦ Transmission Support - Mounting Plate 42A - 3282/42A-
♦ Hose Clamps - Up To 25 mm - 3094-
♦ Tensioning Strap - T10038-
♦ Engine Bung Set - VAS6122-
♦ Insert Tool - 18mm - T10179-
♦ Socket - Xzn 14 - T10061-

♦ Engine Support - Basic Set Square Pipe - T40091/1- (quantity

2)
♦ Engine Support - Basic Set Movable Joint - T40091/3- (quan‐
tity 2)
♦ Engine Support - Supplement Kit Spindle - T40093/3- (quan‐
tity 2) from the Engine Support - Supplement Kit - T40093A-
♦ Engine Support Brackets - T40093/3-6- (quantity 2)
Removing
– Lift the vehicle, all four mounts from lifting platform at the same
height.
– Move the selector lever into »P«.
– Remove the engine cover. Refer to ⇒ Rep. Gr. 10 ; Engine
Cover; Engine Cover, Removing and Installing .
– Remove the air filter housing. Refer to ⇒ Rep. Gr. 24 ; Air
Filter; Air Filter Housing, Removing and Installing .
– Remove the battery and the battery tray -1- -arrows-. Refer to
⇒ Electrical Equipment; Rep. Gr. 27 ; Battery, Removing and
Installing .
3. Transmission, Removing and Installing 73

– 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. 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.
– Remove the charge air pipe. Refer to ⇒ Rep. Gr. 21 ; Over‐

view - Charge Air System .
– Place a lint-free cloth on to transmission fluid cooler and trans‐
mission to absorb escaping coolant.
WARNING
Risk of scalding due to hot steam and hot coolant.

♦ The cooling system is under pressure when the engine is
warm.
♦ Reduce the pressure by covering the coolant reservoir cap
with cloths and carefully opening.

– Clamp the coolant hose with the Hose Clamps - Up To 25mm

- 3094- .
– Loosen the hose clamps -arrows- and remove the coolant ho‐
ses from the transmission fluid cooler.
– Remove the bolts -1- and move the Transmission Coolant
Valve - N488- to the side. Tightening specification. Refer to
– Seal the transmission fluid cooler connections with plugs tak‐
en from Engine Bung Set - VAS6122- .
– Remove the starter -A-. Refer to ⇒ Electrical Equipment; Rep.

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

– Release the Mechatronic connector twist lock -1- by turning it
»counter-clockwise« and remove the connector.
– Remove all upper engine/transmission connecting bolts.
These tools are suitable for this.


One bolt is located inside the hole for the starter -arrow-. Use
Socket - Xzn 14 - T10061- to remove the bolt.
– 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.
– Attach the Engine Support Bridge - 10-222A- as follows:
The following are needed:
♦ Engine/Gearbox Support Shackle (2 pc.) - 10-222A/12- (quan‐
tity: 2) (are needed if the Spindles from the Engine Support
Bridge cannot be engaged in the engine lifting eyes).
(quantity 2)
2)
tity 2)
♦ Engine Support - Supplement Kit - Spindle - T40093/3- (quan‐
tity: 2)
– Insert the Engine Support Bridge - Engine Support 29 -

10-222A/29- between the fender bolting edge and the fender
bolting plate underneath it on both sides of the vehicle.
♦ Installation position:
“L” = -1- Adapter is installed on the “right” side of the vehicle
( Adapter locks in the hole on the fender).
“R” (not illustrated here), Adapter is installed on the “left” side of

the vehicle.
The arrow -2- always points in driving direction
– Slide the Engine Support Bridge - Engine Support 18 -

10-222A/18- and two Engine Support - Basic Set Movable
Joint - T40091/3- onto the Engine Support Bridge - 10-222A- .
– Tighten the Engine Support Bridge - 10-222A- on the Engine
Support Bridge - Engine Support 29 - 10-222A/29- .
-A- = Engine Support Brackets - T40093/3-6- (⇒ next illustration).
– Remove the filler tube for the windshield washer system wash‐
er fluid reservoir. Refer to ⇒ Electrical Equipment; Rep. Gr.
92 ; Windshield Washer System; Windshield Washer Fluid
Reservoir, Removing and Installing .

– If present, remove wires from the front area of both longitudinal

members -arrow-. Do not disconnect line system.
– Place the Engine Support Brackets - T40093/3-6- on both lon‐
gitudinal members (the right longitudinal member is illustrated
here).
– If necessary, carefully unclip the A/C system pipe in the front
area. Do not disconnect the line system. Refer to ⇒ Heating,
Ventilation and Air Conditioning; Rep. Gr. 87 ; Coolant Circuit;
Component Location Overview - Coolant Circuit .
• The Engine Support Brackets - T40093/3-6- locks respectively
with the pins -A- behind the tab on the longitudinal member
-arrow-.
– Install the Engine Support - Supplement Kit - Spindle -
T40093/3- .
– Connect the Engine Support - Supplement Kit - Spindle -
T40093/3- to the Engine Support Bridge - 10-222A- using the
Engine Support - Basic Set Square Pipe - T40091/1- and ten‐
sion it (⇒ previous illustration).
– Then engage the spindles in the lifting eyes.
– Pretension the engine/transmission assembly and Engine
Support Bridge via the Spindles .
– 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 .
them up.
– If equipped, disconnect the connector -1- from the Oil Level

Thermal Sensor - G266- .

– Remove the bolts -11- and then remove the pendulum support
from the transmission.
– Secure the subframe before removing. Refer to ⇒ Suspen‐
sion, Wheels, Steering; Rep. Gr. 40 ; Subframe; Subframe,
Securing .
Note
If the subframe is not secured, a vehicle alignment must be per‐

formed later.
– Remove the subframe without the steering gear. Refer to ⇒

Suspension, Wheels, Steering; Rep. Gr. 40 ; Subframe; Sub‐
frame without Steering Gear, Removing and Installing .
– Remove both driveshafts from the transmission. Refer to ⇒
Suspension, Wheels, Steering; Rep. Gr. 40 ; Driveshaft, Re‐
moving and Installing .
– Secure the driveshafts to the suspension strut using a Ten‐

sioning Strap - T10038- .
Do not damage the surface of the shafts.
– Remove the bolts -1 and 2- from the transmission bracket

-A-.
Always replace the bolts.
– Lower the engine/transmission approximately to the dimen‐

sion -a- using the spindles on the Engine Support Bridge -
10-222A- .
Dimension -a- = approximately 50 mm

– Remove the transmission bracket in direction of -arrow-.
To remove the transmission “0D9”, the Transmission Support -

3282- is equipped with the Transmission Support - Mounting Plate
- 3282/42A- and positioned on the Engine and Gearbox Jack -
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- .
– 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
♦ Contrary to the illustration of the Adjusting Plate , the front

support element is shown attached to the transmission with an
M10 x 50 mm bolt -arrow-. Install a M12 bolt between the
mount and the transmission housing.
♦ DSG transmission 02E “AWD” is shown in the illustration. The
support elements on the “0D9” “FWD” transmission are iden‐
tical.
– 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 the transmission from the engine (alignment
sleeves), and »also pay attention to the selector lever cable«.
Tilt the transmission to the left by adjusting the spindle for the
Transmission Support - 3282- .

– Slightly turn and lower the transmission. Make sure that the
right flange shaft -1- is guided past when lowering the inter‐
mediate plate -arrow-.
Note
Pay attention to all of the lines when lowering the transmission.
Transmission, transporting. Refer to

Secure the transmission on the assembly stand. Refer to
Install the transmission. Refer to
3.1.2 Transmission, Removing, Vehicles with

Turbo Diesel Engine
Brief Description
The transmission is removed downward separately.
»From above«:
The battery, air filter and starter are removed. Engine and trans‐
mission are supported before the left subframe mount is removed.
»From underneath«:
The -subframe- is removed together with the
-pendulum support- and -both control arms-. The -steering gear-
remains in the vehicle.
Both driveshafts are disconnected from the transmission and re‐
main inside the wheel bearing housings. Occasionally they will be
moved to the side, but they still remain on the vehicle.

♦ Transmission Support - 3282-
♦ Transmission Support - Mounting Plate 42A - 3282/42A-
♦ Support Elements for transmission (determine when mounting
the Mounting Plate on the Transmission Support )
♦ Transmission Support - Pins 29 - 3282/29-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Engine and Gearbox Jack - VAS6931-
♦ Hose Clamps - Up To 25mm - 3094- or Hose Clamps - Up To
40mm - 3093-
♦ Engine Support - Basic Set - T40091-

♦ Engine Support - Supplement Kit - T40093A-

♦ Engine Bung Set - VAS 6122-
Removing
– 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 engine cover. Refer to ⇒ Rep. Gr. 10 ; Engine
– Remove the air filter housing. Refer to ⇒ Rep. Gr. 23 ; Air
Filter; Air Filter Housing, Removing and Installing .
– Remove the battery and the battery tray -1- -arrows-. Refer to
⇒ Electrical Equipment; Rep. Gr. 27 ; Battery, Removing and
Installing .
– 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. 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.
– Place a lint-free cloth on to transmission fluid cooler and trans‐

mission to absorb escaping coolant.
WARNING
Risk of scalding due to hot steam and hot coolant.

♦ The cooling system is under pressure when the engine is
warm.
♦ Reduce the pressure by covering the coolant reservoir cap
– Clamp the coolant hose with the Hose Clamps - Up To 25mm

- 3094- .
– Loosen the hose clamps -arrows- and remove the coolant ho‐
ses from the transmission fluid cooler.
– If equipped, remove the bolts -1- and move the Transmission
Coolant Valve - N488- to the side. Tightening specification.
Refer to
– Seal the transmission fluid cooler connections with plugs tak‐
en from Engine Bung Set - VAS 6122- .

– Remove the starter -A-. Refer to ⇒ Electrical Equipment; Rep.

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

– Release the Mechatronic connector twist lock -1- by turning it
»counter-clockwise« and remove the connector.
– Remove all upper engine/transmission connecting bolts.
These tools are suitable for this.

One bolt is located inside the hole for the starter -arrow-. Use
Socket - Xzn 14 - T10061- to remove the bolt.
– Remove windshield wiper arms. Refer to ⇒ Electrical Equip‐
ment; Rep. Gr. 92 ; Windshield Wiper System; Windshield
Wiper Arms, Removing and Installing .
– Remove the plenum chamber cover. Refer to ⇒ Body Exterior;
Rep. Gr. 50 ; Bulkhead; Plenum Chamber Cover, Removing
and Installing .
– 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.

– Attach the Engine Support Bridge - 10-222A- as follows:

The following are needed:
♦ Engine Support Bridge - Engine Support 31 - Adapter 1 -
10-222A/31-1-
♦ Engine Support Bridge - Engine Support 31 - Adapter 2 -
10-222A/31-2-
♦ Engine Support - Basic Set - Square Pipe - T40091/1-
♦ Engine Support - Basic Set Movable Joint - T40091/3-
♦ Engine Support - Supplement Kit Spindle - T40093/3-
♦ Engine Support Brackets - T40093/3-6-
♦ Engine/Gearbox Support Shackle (2 pc.) - 10-222A/12-
– Remove the caps over the suspension strut threaded connec‐
tions.
– Place the Engine Support Bridge - Engine Support 31 Adapter
1 - 10-222A/31-1- and Engine Support Bridge - Engine Sup‐
port 31 Adapter 2 - 10-222A/31-2- on the suspension strut
mounts.
The tabs -arrow- face the engine compartment.
– Slide the Engine Support - Supplement Kit Adapter 3 -

T40091/3- onto the Engine Support Bridge - 10-222A- .
– Fasten the Engine Support Bridge - 10-222A- on the Engine
Support Bridge - Engine Support 31 Adapter 1 - 10-222A/31-1-
and on the Engine Support Bridge - Engine Support 31 Adapt‐
er 2 - 10-222A/31-2- .
-A- = Engine Support Brackets - T40093/3-6- (⇒ next illustration)

– Remove fuel filter and set off to the side. Do not open the line
system. Refer to ⇒ Rep. Gr. 20 ; Overview - Fuel Filter .
– If present, remove wires from the front area of the tab on the
longitudinal member -arrow-. Do not disconnect line system.
– Position the Engine Support Brackets - T40093/3-6- on the
right longitudinal member.
– If necessary, carefully unclip the A/C system pipe in the front
area. Do not disconnect the line system. Refer to ⇒ Heating,
Ventilation and Air Conditioning; Rep. Gr. 87 ; System Over‐
view - Refrigerant Circuit .
• The Engine Support Brackets - T40093/3-6- locks with the pins
-A- behind the tab on the longitudinal member -arrow-.
– Install the Engine Support - Supplement Kit Spindle -
T40093/3- .
– Connect the Engine Support - Supplement Kit Spindle -
T40093/3- over the Engine Support - Basic Set Square Pipe -
T40091/1- with the Engine Support Bridge - 10-222A- and
tension it (⇒ previous illustration).
• The Engine Support - Basic Set Square Pipe - T40091/1- must
be flush with the Engine Support - Basic Set Movable Joint -
T40091/3- and the Engine Support - Supplement Kit Spindle
- T40093/3- (⇒ previous illustration).
– Then engage the Spindles in the lifting eyes, as shown.
– Pretension the engine/transmission assembly and Engine
Support Bridge - 10-222A- via the Spindles .
– Loosen left and right front wheel bolts.
– Lift the vehicle, all four mounts from lifting platform at the same
height.
– Remove the front wheels.
them up.

– If equipped, disconnect the connector -1- from the Oil Level

Thermal Sensor - G266- .
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.
– Disconnect the exhaust system at the clamping sleeve and

remove the exhaust system bracket from the subframe
-arrows-. Refer to ⇒ Rep. Gr. 26 ; Exhaust Pipe/Muffler;
Overview - Muffler .
– Tie up the front exhaust pipe.
– Remove the bolts -11- and then remove the pendulum support
from the transmission.
– Secure the subframe before removing. Refer to ⇒ Suspen‐
sion, Wheels, Steering; Rep. Gr. 40 ; Subframe; Subframe,
Securing .
Note
If the subframe is not secured, a vehicle alignment must be per‐

formed later.
– Remove the subframe without the steering gear. Refer to ⇒

Suspension, Wheels, Steering; Rep. Gr. 40 ; Subframe; Sub‐
frame without Steering Gear, Removing and Installing .
– If equipped, remove the heat shield above the right driveshaft

-arrows-.
– Remove both driveshafts from the transmission. Refer to ⇒
Suspension, Wheels, Steering; Rep. Gr. 40 ; Driveshaft, Re‐
moving and Installing .

– Secure the driveshafts to the suspension strut using a Ten‐

sioning Strap - T10038- .
Do not damage the surface of the shafts.
– Remove the bolts -1 and 2- from the transmission bracket

-A-.
Always replace the bolts.
– Lower the engine/transmission approximately to the dimen‐

sion -a- using the spindles on the Engine Support Bridge -
10-222A- .
Dimension -a- = approximately 50 mm
– Remove the transmission bracket in direction of -arrow-.

To remove the transmission “0D9”, the Transmission Support -

3282- is equipped with the Transmission Support - Mounting Plate
- 3282/42A- and positioned on the Engine and Gearbox Jack -
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- .
– Install the mounting element as illustrated on the Transmission
Support - Mounting Plate 42A - 3282/42 A- .
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
♦ Contrary to the illustration of the Adjusting Plate , the front

support element is shown attached to the transmission with an
M10 x 50 mm bolt -arrow-. Install a M12 bolt between the
mount and the transmission housing.
♦ DSG transmission 02E “AWD” is shown in the illustration. The
support elements on the “0D9” “FWD” transmission are iden‐
tical.
– 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 the transmission from the engine (alignment
sleeves), and »also pay attention to the selector lever cable«.
Tilt the transmission to the left by adjusting the spindle for the
Transmission Support - 3282- .
– Slightly turn and lower the transmission. Make sure that the
right flange shaft -1- is guided past when lowering the inter‐
mediate plate -arrow-.
Note
Pay attention to all of the lines when lowering the transmission.
Transmission, transporting. Refer to

Secure the transmission on the assembly stand. Refer to
Install the transmission. Refer to

3.2 Transmission, Installing
Caution


♦ Bolts - Engine to Transmission Connecting
♦ Bolts - Subframe Mount
♦ Lockwashers - Selector Mechanism Cable
Note
♦ Refer to “Transmission, Removing”

⇒ “3.1 Transmission, Removing”, page 72 for a list of the spe‐
cial tools needed.
♦ After installing a »new« transmission, reprogram the immobil‐
izer.
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) 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.

– Place the transmission with the Transmission Support - 3282-

on the Engine and Gearbox Jack - VAS 6931- .
vehicle. The arrow symbol on the Transmission Support -
Mounting Plate 42A - 3282/42A- points in the direction of travel
of the vehicle.
– Tilt the transmission to the left by adjusting the spindles on the
Transmission Support - 3282- . The lift the transmission.
Pay attention to the selector lever cable when lifting the trans‐
mission. Guide the cable into the cable bracket as early as
possible.
The cable is not lubricated.
– Align the transmission to the engine and position on the cyl‐
inder block.
Guide the engine and transmission together by hand until the en‐
tire surface of both flanges come into contact with one another.
– Adjust the transmission mount until the engine and transmis‐
sion “are aligned”.
– Turn the crankshaft slightly if necessary.
Be careful not to get any lines caught when installing the trans‐
mission.
– Tighten the bolts -5 through 9- to the tightening specification.

– After transmission was bolted to engine at bottom, remove the
Transmission Support - 3282- from transmission.
– Tighten the upper engine/transmission bolts -1, 3 and 10- to
the tightening specification using the Insert Tool - 18mm -
T10179- .
The bolt -3- is located in the starter hole. Use the Socket - Xzn 14
- T10061- for this bolt.
– Align the engine/transmission assembly free of tension. Refer
to ⇒ Engine Mechanical, Fuel Injection and Ignition; Rep. Gr.
10 ; Subframe Mount; Subframe Mount, Adjusting .

Install the left subframe mount as follows:

– Replace all the bolts -1 and 2-.
– Install the new bolt first hand-tight.
– Install the bolts -1- in the transmission bracket -A-.
– 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 .
– Pry the transmission bracket -A- into the seat using a screw‐
driver while tightening the bolts -2-.
WARNING
Remove the Engine Support Bridge - 10-222A- only when the

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

– Install the starter. Refer to ⇒ Electrical Equipment; Rep. Gr.
27 ; Starter; Starter, Removing and Installing .
Connect the connector -A- on the DSG Transmission Mechatronic

- J743- as follows:
– The arrow -D- on the DSG Transmission Mechatronic - J743-
-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 direction of -arrow-.
– Attach the drive axles to the transmission. Refer to ⇒ Sus‐
pension, Wheels, Steering; Rep. Gr. 40 ; Drive Axle; Drive
Axle, Removing and Installing .
– Install the heat shield over the right drive axle, if equipped.
Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive
Axle; Drive Axle, Removing and Installing .
– Install the subframe. Refer to ⇒ Suspension, Wheels, Steer‐
ing; Rep. Gr. 40 ; Subframe; Subframe with Steering Gear,

– Attach the pendulum support to the transmission by tightening

the bolts -11-. Refer to ⇒ Rep. Gr. 10 ; Subframe Mount;
Overview - Subframe Mount .

– Selector lever cable lock washers -arrows- must be replaced.

page 68 .
– Install the charge air pipe. Refer to ⇒ Engine Mechanical, Fuel
Injection and Ignition; Rep. Gr. 21 ; Charge Air System; Over‐
view - Charge Air System .
– Install the coolant hoses on the transmission fluid cooler.
– Attach the cable bracket to the transmission cover.
– Install the battery tray and the battery. Refer to ⇒ Electrical
Equipment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and
Connecting .
♦ Gasoline engine. Refer to ⇒ Rep. Gr. 24 ; Air Filter; Air Filter
– Install the engine cover. Refer to ⇒ Rep. Gr. 10 ; Engine
– Check the coolant level and fill if necessary. Refer to ⇒ Engine
Mechanical, Fuel Injection and Ignition; Rep. Gr. 19 ; Cooling
System/Coolant; Coolant, Draining and Filling .
– Check the fluid level and fill if necessary. Refer to
– Install the lower section of the left front wheel housing liner.
– Attach the front wheels. Refer to ⇒ Suspension, Wheels,
Steering; Rep. Gr. 44 ; Wheels, Tires; Wheel Bolts, Tightening
Specifications .
♦ Transmission to engine. Refer to
♦ Transmission bracket to transmission. Refer to
⇒ “4 Subframe Mount”, page 97 .
♦ Cable bracket on the transmission cover. Refer to
♦ Subframe mount to transmission bracket. Refer to
⇒ “4.1 Overview - Subframe Mount”, page 97 .

3.3 Transmission Tightening Specifications

Transmission to Engine
Item Bolt Nm
1 M12 x 55 80
• With Insert Tool -
18mm T10179:
“65 Nm”
2 M10 x 45 40
♦ Starter to trans‐
mission
3 M12 x 55 80
♦ Is accessible on‐
ly through the
opening in the
removed starter
4 M10 x 45 40
or M10 x 40
♦ Starter to trans‐
mission
5 M12 x 65 80
or M12 x 70
6 M10 x 50 40
7 M10 x 50 40
8 M10 x 50 40
9 M12 x 65 80
or M12 x 70
or M12 x 80
10 M12 x 55 80
• With Insert Tool -
18mm T10179:
“65 Nm”
A Alignment sleeve for centering
Component Tightening Specification

Cable bracket on the transmis‐ 10 Nm
sion cover
Transmission Coolant Valve - 9 Nm
N488- bolts

4 Subframe Mount
⇒ “4.1 Overview - Subframe Mount”, page 97 .
4.1 Overview - Subframe Mount
1 - Bolt
❑ For the tightening spec‐
ification. Refer to ⇒ En‐
gine Mechanical, Fuel
Injection and Ignition;
Rep. Gr. 10 ; Subframe
Mount; Overview - Sub‐
frame Mount .
2 - Engine Support
❑ Refer to ⇒ Engine Me‐
chanical, Fuel Injection
and Ignition; Rep. Gr.
10 ; Subframe Mount;
Overview - Subframe
Mount .
3 - Engine Mount
❑ Refer to ⇒ Engine Me‐
chanical, Fuel Injection
and Ignition; Rep. Gr.
10 ; Subframe Mount;
Overview - Subframe
Mount .
4 - Bolt
Mount; Overview - Sub‐
frame Mount .
5 - Bolt
Mount; Overview - Subframe Mount .
6 - Bolt
❑ For the tightening specification. Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition; Rep. Gr. 10 ;
Subframe Mount; Overview - Subframe Mount .
7 - Bolt
8 - Pendulum Support
9 - Bolt
❑ For pendulum support to subframe
10 - Bolt
❑ For pendulum support to transmission
4. Subframe Mount 97
❑ Transmission with threaded insert. Refer to
⇒ Fig. ““Transmission with Threaded Insert (for Example Heli Coil) for Attaching the Pendulum Support”“ ,
page 99
11 - Bolt
❑ For pendulum support to transmission
❑ Transmission with threaded insert. Refer to
⇒ Fig. ““Transmission with Threaded Insert (for Example Heli Coil) for Attaching the Pendulum Support”“ ,
page 99
12 - Bolt
❑ 60 Nm + 90°
❑ For transmission mount to transmission bracket
❑ Tightening sequence. Refer to ⇒ page 99 .
13 - Bolt
❑ 60 Nm + 90°
❑ Quantity: 2
❑ For transmission mount to transmission bracket
14 - Transmission Mount
❑ Check the adjustment. Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition; Rep. Gr. 10 ; Subframe
Mount; Subframe Mount, Checking Adjustment
❑ Adjusting. Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition; Rep. Gr. 10 ; Subframe Mount;
Subframe Mount, Adjusting
15 - Bolt
❑ Transmission mount to chassis
Subframe Mount; Subframe Mount, Adjusting .
16 - Bolt
❑ 40 Nm + 90°
❑ For transmission bracket to transmission
17 - Transmission Bracket
❑ Illustration does not correspond to version in vehicle
18 - Bolt
❑ 40 Nm 90°
❑ For transmission bracket to transmission

Transmission with Threaded Insert (for Example “Heli Coil”) for

Attaching the Pendulum Support
Note
♦ There are threaded inserts (for example “Heli Coil”) in the pen‐
dulum support fastening holes.
♦ Identified by: collar on the first thread -arrow-.
♦ Make sure to use the appropriate bolts and observe the tight‐
ening specification. Refer to ⇒ Engine Mechanical, Fuel In‐
jection and Ignition; Rep. Gr. 10 ; Subframe Mount; Overview
- Subframe Mount ..
Install the Left Subframe Mount as Follows:

– Replace all the bolts -1 and 2-.
– Install the new bolt first hand-tight.
– Install the bolts -1- in the transmission bracket -A-.
– Pry the transmission bracket -A- into the seat using a screw‐
driver while tightening the bolts -2-.
4. Subframe Mount 99
5 Transmission, Transporting
♦ Engine Sling - 2024A-
♦ Transmission Support Jig - 3336-
♦ Shop Crane - VAS6100-
Always secure heaving parts when transporting them.
Remember there is oil in the transmission. Do not turn the trans‐
mission with the vents facing downward when transporting or
when it is on the assembly stand. The oil will leak out.
Note
Remove the bleed cap if necessary and use oil-tight plugs.
Transmission, Transporting
– Install the Engine Sling - 2024A- on the transmission and se‐
cure with the clamp.
The transmission can also be lifted using the Transmission Sup‐

port Jig - 3336- .

6 Transmission, Disassembling and

Assembling
6.1 Overview - Transmission
1 - Transmission Cover
ling. Refer to
page 30 .
2 - Seal
3 - Bolt
❑ For attaching the DSG
Transmission Mecha‐
tronic - J743- to the
transmission housing
❑ Tightening specification
and sequence. Refer to
⇒ Fig. ““Tightening
Specification and Se‐
quence for DSG Trans‐
mission Mechatronic -
J743- ”“ , page 30
❑ Quantity: 10
4 - DSG Transmission Mecha‐
tronic - J743-
❑ Allocate using the trans‐
mission code letters.
Refer to the Parts Cata‐
log
❑ Removing and Installing
with transmission instal‐
led. Refer to
page 30 .
❑ Removing and installing
with transmission re‐
moved. Refer to
⇒ “1.2.2 DSG Transmission Mechatronic J743 , Removing and Installing, Transmission Removed”, page
39
5 - Bolt
⇒ Fig. ““Tightening Specification and Sequence for DSG Transmission Mechatronic -J743- ”“ , page 30
❑ For attaching the transmission cover with seal to the transmission housing
❑ Quantity: 5
6 - Clutch End Cover
❑ For the dual clutch -7-.
❑ Removing and installing. Refer to ⇒ “1.2 Clutch End Cover, Removing and Installing”, page 15 .
6. Transmission, Disassembling and Assembling 101

7 - Dual Clutch
❑ Removing. Refer to ⇒ “1.3 DSG® Clutch, Removing”, page 19 .
❑ Installing. Refer to ⇒ “1.4 DSG® Clutch, Installing”, page 21 .
8 - Bleed Pipe
❑ Pressed into the transmission housing
9 - Bleed Cap
❑ Placed on bleed pipe -8-.
10 - Nut
❑ 20 Nm
11 - Selector Lever
❑ Insert so that master spline aligns with shift rod
12 - Seal
❑ For the selector shaft
❑ Replacing. Refer to ⇒ “2.9 Selector Shaft Seal, Replacing”, page 69 .
13 - Bolt
❑ 20 Nm + 90°
14 - Transmission Oil Cooler
⇒ “8.1 Transmission Fluid Cooler, Removing and Installing”, page 105 .
15 - O-Rings
16 - Cable Mounting Bracket
❑ For selector lever cable
17 - Bolt
❑ 20 Nm + 90°
❑ Quantity: 2
18 - Filter Housing
❑ 20 Nm
19 - O-Ring
20 - Transmission Fluid Filter
❑ Information on changing filter ⇒ “8.3 Transmission Fluid Filter, Removing and Installing”, page 110
❑ Replacing. Refer to ⇒ “9 Transmission Fluid”, page 113 .
21 - Ignore, discontinued
22 - Ignore, discontinued
23 - Alignment Pin
❑ Quantity: 2
❑ For centering the transmission fluid pump to the transmission housing
24 - Seal

25 - Transmission Oil Pump

26 - Transmission Fluid Pump Cover
❑ With seal
27 - Bolt
⇒ Fig. ““Tightening Specification and Sequence of the Transmission Fluid Pump Cover -A-.”“ , page 30
28 - Bolt
❑ There are different bolts for the transmission fluid pump. Refer to ⇒ page 109
❑ Quantity: 4
29 - Overflow Pipe
❑ 3 Nm
❑ Plastic
❑ To drain the transmission fluid, remove the drain and check plugs. Refer to -item 31-
⇒ Item 31 (page 103) , and remove the overflow pipe.
❑ The length of the overflow pipe determines the fluid level inside the transmission
❑ Allocate according to the Parts Catalog.
30 - Seal
31 - Transmission Fluid Drain- and Check Plug
❑ 45 Nm
❑ There is an overflow pipe with a 8 mm inner hex behind this bolt -item 29- ⇒ Item 29 (page 103)
❑ Drain the transmission fluid via the drain- and check plug and removed overflow pipe
6. Transmission, Disassembling and Assembling 103

7 Securing on Engine and Transmis‐

sion Holder
♦ Holding Plate - VW309-
♦ or Holding Plate - VW309A-
♦ Transmission Support - VW353-
♦ Engine and Gearbox Bracket - VAS6095A-
Remember there is oil in the transmission. Do not turn the trans‐
mission with the vents facing downward when transporting or
when it is on the assembly stand. The fluid will leak out.
Note
Remove the bleed cap if necessary and seal using suitable oil-
tight plugs.
Secure the transmission on the Transmission Support - VW353- .

8 Transmission Fluid Circuit

⇒ “8.1 Transmission Fluid Cooler, Removing and Installing”, page
105
⇒ “8.2 Transmission Fluid Pump, Removing and Installing”, page
107
page 110
8.1 Transmission Fluid Cooler, Removing

and Installing
♦ Hose Clamps - Up To 25mm - 3094-
♦ Engine Bung Set - VAS6122-
Caution


♦ Bolts - Transmission Fluid Cooler
♦ O-rings - Transmission Fluid Cooler
Removing
– Remove the battery and the battery tray if necessary. Refer to
⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Battery, Dis‐
connecting and Connecting .
– Place lint-free cloth on to transmission fluid cooler and trans‐
mission to absorb exiting coolant.
WARNING
Risk of burning due to hot steam and hot coolant.

♦ When engine is warm, the cooling system is under pres‐
sure.
♦ Reduce pressure by cover coolant expansion tank cap
8. Transmission Fluid Circuit 105

– Disconnect the coolant hoses with Hose Clamps - Up To

25mm - 3094- and remove from the transmission fluid cooler.
– Remove the bolts -A- and the transmission fluid cooler -B-.
Caution
Coolant must not drip into transmission!
Installing
– Replace the O-rings -C- on the transmission fluid cooler -B-.
– Mount the transmission fluid cooler -B-, while doing this, pay
attention to the O-rings -C-.
– Install and tighten the new bolts -arrows-.


– 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 if they were removed
earlier. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery;
Battery, Disconnecting and Connecting .
– Check the coolant level and add if necessary. Refer to ⇒ En‐

gine Mechanical, Fuel Injection and Ignition; Rep. Gr. 19 ;
Cooling System/Coolant; Coolant, Draining and Filling .
– After repairing, check the transmission fluid level and fill. Refer
to ⇒ “9.1 Transmission Fluid Level, Checking”, page 113 .
Caution
Do not start engine during coolant level test if the transmission

fluid has not been filled yet.
♦ Transmission fluid cooler at transmission. Refer to
8.2 Transmission Fluid Pump, Removing

and Installing
♦ Wrench - Pump/Injector Long Reach - T10054-
Brief Description
Transmission fluid pump can be replaced without removing trans‐
mission. The vehicle must be raised and any covers installed on
bottom of front end must be removed. The control arm to sus‐
pension strut connection does not need to be separated. The
driveshaft also does not have to be removed. It is not necessary
to perform a “basic setting”. Only the dual-clutch transmission flu‐
id and transmission fluid pump cover have to be replaced.
Removing
– Loosen the left front wheel bolts.
– Raise the vehicle and remove the left front wheel.
– Remove the left front wheel housing liner. Refer to ⇒ Body
Exterior; Rep. Gr. 66 ; Wheel Housing Liner; Front Wheel
Housing Liner, Removing and Installing .


– Remove the Transmission fluid drain- and check plugs
-arrow- and drain the transmission fluid.
Caution

transmission.
A plastic overflow pipe is located in this hole (with 8 mm hex

socket head). Its length determines the fluid level in the trans‐
mission.
– Remove this overflow pipe and drain the remaining transmis‐
sion fluid.
– Reinstall the overflow pipe.
– Replace the bolt seal -arrow-.

In regard to »contaminated fluid«, also read the information on
changing the oil filter. Refer to
page 110 .
– The Used Oil Collection and Extraction Unit - SMN372500- or
a Drip Tray remains under the transmission.
Caution
Fluid will leak out of the cover when the bolts are removed. Risk
of injury due to hot transmission fluid.
– The bolts -arrows- and remove the transmission fluid pump

cover -A-.
Note
Always replace the cover and the transmission fluid pump bolts
after removing.

– Remove the bolts -arrows-. Remove the transmission fluid

pump -1- from the alignment pin and the input shaft.
Remove the top bolt with the Wrench - Pump/Injector Long Reach
- T10054- .
Installing
– Install the transmission fluid pump 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 transmission fluid pump, pay attention
to the driveshaft splines -A- and the correct seating on the
alignment pins -C-.
Different Transmission Fluid Pump Bolts -1-

All Four Bolts -arrows- with Flat Heads
Replace the bolts after removing them.
Tightening Specification
♦ 5 Nm + +90° (1/4 turn)

3 Bolts with Flat Head, Top Bolt -arrow- with Countersunk Head
Replace the bolts after removing them.
Tightening Specification
♦ Countersunk head bolt: 8 Nm without tightening angle (tighten
with the Wrench - Pump/Injector Long Reach - T10054- )
♦ Flat head screws: 8 Nm + 90° (1/4 turn)
– Mount the new transmission fluid pump cover -A-. Install the
stages.
Transmission does not have oil. »New« oil must now be added
and adjust to the correct oil level. Refer to
⇒ “9 Transmission Fluid”, page 113 .
– Install the left front wheel housing liner. Refer to ⇒ Body Ex‐
terior; Rep. Gr. 66 ; Wheel Housing Liner; Overview - Front
– Install the wheel. Refer to ⇒ Suspension, Wheels, Steering;
Rep. Gr. 44 ; Wheels, Tires; Wheel Bolts, Tightening Speci‐
fications .
♦ Refer to ⇒ “1.1 Overview - Mechatronic”, page 28
♦ Transmission fluid pump to the transmission housing. Refer to
⇒ page 109 .
♦ Transmission fluid pump cover to transmission housing. Refer
to
⇒ Fig. ““Tightening Specification and Sequence of the Trans‐
mission Fluid Pump Cover -A-.”“ , page 30 .
8.3 Transmission Fluid Filter, Removing

and Installing
When to Change Transmission Fluid Filter
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 coolants has gotten into the transmission fluid.
♦ The selector shaft sealing ring was replaced.
♦ The flange seal was replaced.
♦ Leaking Mechatronic covers, DSG® clutch or transmission flu‐
id pump were replaced.
The Filter Must be Replaced If:
♦ The 60,000 km maintenance interval was reached.
♦ Coolant has entered the fluid.
♦ Metal shavings were found in the fluid.

♦ The clutch is burned or has a mechanical fault.
Note
General repair instructions. Refer to

⇒ “3 Repair Information”, page 5 .
Caution


♦ Filter - Transmission Fluid Filter
♦ O-ring - Filter Housing
Removing
– Remove the complete air filter housing:
♦ Vehicles with a gasoline engine. Refer to ⇒ Engine Mechan‐
ical, Fuel Injection and Ignition; Rep. Gr. 24 ; Air Filter; Air
Filter Housing, Removing and Installing
♦ Vehicles with a diesel engine. Refer to ⇒ Rep. Gr. 23 ; Air
Filter; Air Filter Housing, Removing and Installing
– Remove the battery with the battery tray. Refer to ⇒ Electrical

Equipment; Rep. Gr. 27 ; Battery; Battery Tray, Removing and
Installing .
Note
♦ A little bit of fluid remains inside the filter. This will drain out
once the filter is removed.
♦ Lay some cloths down near the filter before removing it.

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

– Wait 10 seconds.
This way the fluid can flow from the filter housing back into the
transmission.
– Remove the filter housing and filter.
– Remove O-ring from filter housing.
Installing
Install in the reverse order of removal while noting the following:
– Clean thoroughly any areas on the transmission that get
stained with transmission fluid.
– Install the transmission fluid filter with the collar on the bottom
-arrow-.
– Install new O-ring on filter housing.
– Install and tighten the filter housing.
Install in reverse order of removal.
– Install the battery tray and the battery. Refer to ⇒ Electrical
Equipment; Rep. Gr. 27 ; Battery; Battery, Removing and In‐
stalling .
– Install the complete air filter housing:
♦ Gasoline engine. Refer to ⇒ Rep. Gr. 24 ; Air Filter; Air Filter
♦ Filter housing. Refer to

9 Transmission Fluid
⇒ “9.1 Transmission Fluid Level, Checking”, page 113
⇒ “9.2 Transmission Fluid, Draining and Filling”, page 116
9.1 Transmission Fluid Level, Checking

♦ Vehicle Diagnostic Tester
♦ Shop Crane - Drip Tray - VAS6208-
♦ Brake Line Tool Kit - Pipe Cutter - VAS6056/2-
♦ Also for some fluid containers Oil Filler - Adapter 6 -
VAS6262/6-
Caution


♦ Seal - Transmission Fluid Drain - and Check Plug
Note the Following Information:
♦ Use the ATF available as a replacement part. Refer to the
Parts Catalog.
♦ It is necessary to use the Oil Filler - Adapter 6 - VAS6262/6-
on some fluid containers.
♦ It may be necessary to shorten the bleed pipe on the Adapter
For Oil Filling - VAS6262A- . Refer to ⇒ page 114 .
9. Transmission Fluid 113

Shorten the Bleed Pipe on the Adapter For Oil Filling - VAS6262A-
as Follows:
– Shorten the pipe to dimension -a-. This assures the pipe on
the Adapter For Oil Filling - VAS6262A- will not touch the bot‐
tom on some fluid containers.
Dimension -a- = 210 mm
Note
Dimension -a- is measured starting from the shaft (the green sur‐
face) on the Adapter For Oil Filling - 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- .
Requirements
♦ The vehicle is level and all hoist supports are the same height.
♦ Noise insulation is removed. Refer to ⇒ Body Exterior; Rep.
♦ Vehicle Diagnostic Tester is connected
♦ To begin working, the fluid temperature should not be higher
than 45 °C (113 °F).
♦ Test temperature: 35 ° to 45 °C (95 ° to 113 °F).
Checking
– Vehicle Diagnostic Tester Connect 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).
The engine is idling in neutral and the selector lever is in “P”.

– Move the Used Oil Collection and Extraction Unit -
SMN372500- or a Drip Tray under the transmission near the
transmission fluid drain and check plug.

– Always replace the seal 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 seal as soon as all the fluid
has drained out (it starts to drip).
– If no transmission fluid comes out, then fill.
Adding

tight.
– Fill 1.0 liters (1.05 quarts) of transmission fluid.
– Remove the Adapter for Oil Filling - VAS6262A- at the quick-
release coupling and check it.
If ATF Flows Out of Adapter Hole:
Oil must not be topped off.
– Let the excess oil drain.
– As soon as the oil has run out (it begins to drip), remove the
Oil Filler - VAS6262A- and install screw with new seal.
If No Oil Flows Out of Hole:
– Add another liter of transmission fluid.
WARNING
Too little or too much ATF will impair the transmission.
Insert the fluid drain plug and check plug with a new seal and
tighten them.
♦ Transmission fluid drain- and check plug. Refer to
9.2 Transmission Fluid, Draining and Filling

Use the ATF available as a replacement part. Refer to the Parts
Catalog.
Short Description
First, oil temperature is read out. If it is higher than 45 °C (113 °
F), then let the transmission to cool down.
Turn off the engine, remove the overflow pipe and drain any ATF.
Install the overflow pipe and “overfill” the ATF.
Start the engine and drain any excess oil until the oil level has
reached the overflow tube.
♦ Shop Crane - Drip Tray - VAS6208-
♦ Oil Filler - Adapter 6 - VAS6262/6-
Requirements
♦ The engine is off.
♦ The vehicle is level and all hoist supports are the same height.

♦ Noise insulation is removed. Refer to ⇒ Body Exterior; Rep.

♦ The selector level is in “P.”
♦ Vehicle Diagnostic Tester is connected
♦ To begin working, the oil temperature should not be higher
than 45 °C (113 °F).
Procedure
– Follow the rules for clean working conditions when working on
the transmission.
– Only use the ATF for the DSG® transmission available as a
replacement part. Other oils can cause malfunctions or trans‐
mission failure.
WARNING
Risk of injury due to hot transmission fluid.
– Vehicle Diagnostic Tester connect 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).
WARNING

transmission.
– Engine off - do not start!

• The Used Oil Collection and Extraction Unit - SMN372500- or
Drip Tray is placed under the transmission.


A “black plastic overflow tube” is located in this hole (with 8 mm
hex socket head). Its length determines the oil level in the trans‐
mission.
– Remove the overflow pipe -arrow- and let the ATF drain.
About 5 liters (5.28 qt) of oil will drain.
– Install the overflow pipe and tighten it to the tightening speci‐
fication.
page 110 .
tight.

– Fill 5.5 liters (5.8 qts) of transmission fluid.
– To change containers, close the shut-off valve or hold the Oil
Filler - VAS6262A- higher than the transmission.

– Tighten the transmission fluid drain and check plug -arrow-

hand-tight only.
– Start the engine.
– Press the brake pedal and move the selector lever through
each gear for approximately 3 seconds. Then move the se‐
lector lever back into “P”.
– Do not turn off the engine.
– Check the ATF level and fill if necessary. Refer to
♦ Overflow Pipe. Refer to

10 Special Tools
Special tools and workshop

equipment required
♦ Engine Support Bridge -
10-222A-
Engine Support 29 -
10-222A/29-
Engine Support 18 -
10-222A/18-
♦ Engine/Gearbox Support
Shackle (2 pc.) - 10-222A/
12- (quantity 2)
♦ Transmission Support -
Pins 29 - 3282/29-
3282-

♦ Engine and Gearbox Jack -

VAS6931-
Mounting Plate 42A -
3282/42A-
♦ Hose Clamps - Up To
25mm - 3094-
♦ Engine Bung Set -
VAS6122-
♦ Insert Tool - 18mm -
T10179-
10. Special Tools 121

♦ Torque Wrench 5-50Nm -

VAG1331-
♦ Used Oil Collection and Ex‐
traction Unit - SMN372500-
♦ Shop Crane - Drip Tray -
VAS6208-
♦ Oil Filler - Adapter 2 -
VAS6262/2-
♦ Wrench - Pump/Injector Long Reach - T10054-

♦ Socket - Xzn 14 - T10061-
♦ Puller - Crankshaft/Power Steering Seal - T20143-

2)

tity 2)
♦ Engine Support - Supplement Kit Spindle - T40093/3- (quan‐
tity: 2) from the Engine Support - Supplement Kit - T40093A-

♦ Hose Clip Pliers - VAG1275A-
♦ Engine And Transmission Holder - VAS6095-
♦ Shop Crane - VAS6100-

♦ Also for some oil containers Oil Filler - Adapter 6 - VAS6262/6-
♦ Holding Plate - VW309A-
♦ Transmission Support - VW353-
♦ Press Piece - Shift Rod/Alternator - VW423-

♦ Engine Sling - 2024A-
♦ Transmission Support Jig - 3336-

35 – Gears and Shafts

1 Gears and Shafts, Disassembling
and Assembling
No Repairs to Gears and Shafts
1. Gears and Shafts, Disassembling and Assembling 127

39 – Final Drive, Differential

1 Seals
⇒ “1.1 Component Location Overview - Seals”, page 128 .
⇒ “1.2 Left Seal, Replacing”, page 128 .
⇒ “1.3 Right Seal, Replacing”, page 131 .
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 - Seal
❑ For the right flange shaft
❑ Replacing. Refer to
⇒ “1.3 Right Seal, Re‐
placing”, page 131 .
2 - Right Flange Shaft
3 - Bolt
❑ 30 Nm
4 - Nut
❑ Tightening specifica‐
tion. Refer to
⇒ “6.1 Overview - Trans‐
mission”, page 101 .
5 - Selector Lever
6 - Gearshift Shaft Seal
⇒ “2.9 Selector Shaft
Seal, Replacing”,
page 69 .
7 - Seal
❑ For the left flange shaft
⇒ “1.2 Left Seal, Replac‐
ing”, page 128 .
8 - Left Flange Shaft
9 - Bolt
❑ 30 Nm
1.2 Left Seal, Replacing

♦ Slide Hammer Set - VW771-
128 Rep. Gr.39 - Final Drive, Differential

♦ Seal Installer - Flange Shaft - 3305-

♦ Socket And Extended Bit - T10107A- or
♦ Long Hex Socket - VAG1669-
♦ Slide Hammer Set - Hook - VW771/37-
♦ Sealing Grease - G 052 128-
Removing
• Transmission installed
Note
Observe. Refer to ⇒ “3 Repair Information”, page 5 .
– Lift the vehicle, all four take-up points of lifting platform at same
height.
Note
Do not lower the vehicle onto the floor after loosening central bolt.
– Press the brake and remove the bolt from the left driveshaft
-arrow- (second technician).
– Remove the left front wheel.
– Remove the left drive axle. Refer to ⇒ Suspension, Wheels,
Steering; Rep. Gr. 40 ; Drive Axle; Drive Axle, Removing and
Installing .
– Remove the left transmission flange shaft using the Socket

And Extended Bit - T10107A- .
The bolt has a 6 mm inner hex socket. The bolt can also be re‐
moved and installed using Long Hex Socket - VAG1669- .
1. Seals 129
– To remove and install the flange shaft, install 2 bolts into the
flange and counterhold it using a pry bar.
– Remove the flange shaft.
– Remove seal with Slide Hammer Set - VW771- and Slide

Hammer Set - Hook - VW771/37- .
Installing
– Lightly oil new seal on outer circumference.
with Sealing Grease - G 052 128- .

– Install the seal all the way in without tilting it.
Note
Press the flange shaft against the transmission so that the bolt in
the threaded piece of the differential touches.
– Insert the flange shaft and secure it with bolts.

– Install the left drive axle. Refer to ⇒ Suspension, Wheels,
Steering; Rep. Gr. 40 ; Drive Axle; Drive Axle, Removing and
Installing .
– Install the left front wheel housing liner. Refer to ⇒ Body Ex‐
terior; Rep. Gr. 66 ; Wheel Housing Liner; Overview - Front
– Attach the left front wheel. Refer to ⇒ Suspension, Wheels,
Steering; Rep. Gr. 44 ; Wheels and Tires; Wheel, Changing .
♦ Flange shaft to transmission. Refer to
1.3 Right Seal, Replacing

♦ Seal Installer - Axle Flange - 3158-
♦ Socket And Extended Bit - T10107A-
♦ Long Hex Socket - VAG1669-
♦ Sealing Grease - G 052 128-
Removing
• Transmission installed
Note
General repair instructions. Refer to

⇒ “3 Repair Information”, page 5 .

1. Seals 131
– Disconnect the connector -1- from the Oil Level Thermal Sen‐
sor - G266- , if equipped.
– If equipped, remove the heat shield above the right drive axle
-arrows-.
– Remove the right drive axle from the transmission. Refer to ⇒
Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axle; Drive
Axle, Removing and Installing .
– Remove the nuts -arrows- on the right ball joint.

– Remove the nut from the bracket for the Right Front Level
Control Sensor - G289- if equipped.
– Disengage the right ball joint from the control arm.
– Fasten the right ball joint -2- on the control arm -1- with a nut
-arrow-, as shown in the illustration.

– Secure the right drive axle to the suspension strut using a

Tensioning Strap - T10038- .
Do not damage the surface of the shaft.
– Remove the right transmission flange shaft using the Socket

And Extended Bit - T10107A- .
The bolt has a 6 mm inner hex socket. The bolt can also be re‐
moved and installed using Long Hex Socket - VAG1669- .
– To remove and install the flange shaft, install 2 bolts into the
flange and counterhold it using a pry bar.
– Remove the flange shaft.
– Pry out the sealing ring.
Installing
– Lightly oil new seal on outer circumference.
with Sealing Grease - G 052 128- .
1. Seals 133
– Install the seal all the way in without tilting it.
Note
Press the flange shaft against the transmission so that the bolt in
the threaded piece of the differential touches.
– Insert the flange shaft and secure it with bolts.

– Install the ball joint. Refer to ⇒ Suspension, Wheels, Steering;
Rep. Gr. 40 ; Lower Control Arm and Ball Joint; Overview -
Lower Control Arm and Ball Joint .
– Fasten the drive axle to the flange shaft. Refer to ⇒ Suspen‐
sion, Wheels, Steering; Rep. Gr. 40 ; Drive Axle; Drive Axle,
– Install the heat shield over the right drive axle, if equipped.
Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive
Axle; Drive Axle, Removing and Installing .
♦ Flange shaft to transmission. Refer to


2 Special Tools
♦ Socket And Extended Bit - T10107A-
♦ Slide Hammer Set - VW771-

♦ Seal Installer - Axle Flange - 3158-
♦ Seal Installer - Flange Shaft - 3305-

3 Revision History
DRUCK NUMBER: K0059240321
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 3/20 tory
15 Up‐
date
11.2 08/1 Ma‐ N/A Eric P.
014 4/20 jor
15 Edit
11.2 08/1 Lo‐ 111 Eric P.
014 4/20 cal 670
15 Feed 1
back
11.2 02/1 Link N/A updated ext-rl tags Eric P.
014 3/20 Chec
15 king
11.2 11/2 Fac‐ Added model code and Jim H.
014 5/20 tory chagnes
14 Up‐
date
05.2 5/1/2 Fac‐ N/A Launch for AU1 Golf Jim H.
014 014 tory
New
3. Revision History 137

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Service

Service Department. Technical Information

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

6 Transmission, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

35 - Gears and Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

39 - Final Drive, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

00 – General, Technical Data

1.1 Transmission Identification

GKF - Transmission Code

Reading the Transmission Code on the Transmission Installed

♦ Additionally the transmission code it on top of the transmission

2 Rep. Gr.00 - General, Technical Data

2.1 General Safety Precautions

There is a risk of injury and accident from accidentally engag‐

To Prevent Personal Injury and Damage to Electrical and Elec‐

Risk of damaging electronic components when disconnecting

– Disconnect the battery. Refer to ⇒ Electrical Equipment; Rep.

2.2 Start/Stop System Safety Precautions

Danger of injury through automatic motor starting with vehicles

2.3 Safety Precautions when Tow Starting

Danger of causing damage to the transmission.

The engine cannot be tow started, for example, if the battery is

2.4 Safety Precautions during Road Test

There is a risk of an accident due to distractions and improperly

4 Rep. Gr.00 - General, Technical Data

3.1 General Information

3.2 Clean Working Conditions

♦ Protect the disconnected connectors from dirt and moisture

3.3 General Repair Information

Special Tools and Equipment

6 Rep. Gr.00 - General, Technical Data

Fluid Drain and Check Plug

3.4 Seals, Sealing Rings

3.5 Bolts and Nuts

8 Rep. Gr.00 - General, Technical Data

4.1 Transmission/Engine Allocation

Always use refer to the transmission code letters if a repair re‐

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

4.3 Gear Ratio Calculation

i = Z2 : Z1 (Z1 = number of teeth on the drive gear, Z2 = number

10 Rep. Gr.00 - General, Technical Data

5.1 Component Location Overview - Electrical Components

1 - DSG Transmission Mecha‐

12 Rep. Gr.00 - General, Technical Data

1.1 Overview - Dual Clutch

1 - Dual Clutch with Circlip

Individual Parts of the Disassembled DSG® Clutch

14 Rep. Gr.30 - Clutch

1 - DSG® Clutch/Clutch Hous‐

1.2 Clutch End Cover, Removing and Instal‐

This procedure contains mandatory replaceable parts. Refer

Mandatory Replacement Parts

16 Rep. Gr.30 - Clutch

– Only hold the clutch end cover as shown in this illustration!

– If necessary, clean the sealing surface on the drive plate

– Clean the Clutch Cover Plate Guide Sleeve - T10302- “before

The clutch end cover may not be exposed to direct hammer

18 Rep. Gr.30 - Clutch

– Only remove bushing once circlip is installed.