7 Speed DSG 0dl Eng

Service
Workshop Manual
Arteon 2018 ➤ , Passat 2015 ➤ ,
Passat 2019 ➤ , Passat Variant 2015 ➤ ,
Passat Variant 2019 ➤ , Tiguan 2016 ➤ ,
Tiguan RUS 2017 ➤
7-speed dual clutch gearbox 0DL
Edition 12.2019
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - differential
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Arteon 2018 ➤ , Passat 2015 ➤ , Passat 2019 ➤ , Passat Variant 2015 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 12.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 General safety provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 2
1.3 Notes on tow-starting/towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Safety precautions when using testers and measuring instruments during a road test . . . . 2
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 Allocation gearbox - engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.1 Overview of fitting locations - electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Assembly overview - dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Removing and installing clutch end cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3 Removing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4 Installing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1 Mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.1 Removing and installing mechatronic unit for dual clutch gearbox J743 (gearbox installed)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2 Removing and installing gearbox input speed sender G182 and oil temperature sender in
multi-plate clutch G509 up to gearbox date 05/15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2 Bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.1 Distinguishing between different types of bevel boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.2 Removing and installing bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.3 Detaching bevel box from gearbox - gearbox removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.1 Assembly overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.2 Emergency release from position P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.3 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.4 Moving push-button in the handle to installation position . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.5 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.6 Removing and installing gear selector cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.7 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.8 Checking and adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.9 Renewing selector shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.1 Specified torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.2 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.3 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
5 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Contents i
5.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

6 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
7 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
7.1 Assembly overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
8 Securing to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
9 Gear oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
9.1 Removing and installing gear oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
9.2 Removing and installing gear oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
10 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
10.1 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
10.2 Draining and filling gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

1 Currently, no repairs can be made to gears and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

1 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
1.1 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
1.2 Draining and filling gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
2 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
2.1 Overview of fitting locations - seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
2.2 Renewing left seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
2.3 Renewing right oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
3 Components of bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
3.1 Assembly overview - components of bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
3.2 Renewing bevel box seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
3.3 Renewing needle bearing (polygon bearing) for stub shaft . . . . . . . . . . . . . . . . . . . . . . . . 210
ii Contents
00 – Technical data
1 Safety information
(VRL013748; Edition 12.2019)
⇒ “1.1 General safety provisions”, page 1
⇒ “1.2 Safety measures when working on vehicles with a start/
stop system”, page 2
⇒ “1.3 Notes on tow-starting/towing”, page 2
⇒ “1.4 Safety precautions when using testers and measuring in‐
struments during a road test”, page 2
1.1 General safety provisions

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

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

trical and electronic components, observe the following:
♦ Connect and disconnect measuring and testing devices only
with the ignition switched off.
Caution
Risk of irreparable damage to electronic components when

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

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

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

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

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

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

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

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

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

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

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

The gearbox code can be found on top of the gearbox, near the
starter.
1 - Gearbox code
2 - Day of production
3 - Month of production
4 - Year of production
5 - Serial number
6 - Minute of production
7 - Hour of production
8 - Factory
Note
The gearbox code is also indicated on the vehicle data stickers.

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

Gearbox
♦ The torque of the engine is transmitted via the flywheel to the
dual clutch gearbox. The flywheel and the dual clutch are
joined together by a toothed connection. Together they take
on the function of the dual-mass flywheel.
♦ The gearbox is structured like a manual gearbox. Through op‐
posed hydraulic actuation of the dual clutch, it is operated like
an automatic gearbox. In other words, the gears are engaged
automatically or manually via the Tiptronic system. There is no
clutch pedal.
Selector mechanism
The feedback for the gearbox concerning the selector lever po‐
sition is not transferred by mechanical means via the selector
lever cable and the multifunction switch (gear sensor) any more,
as is the case for the automatic gearbox. The information con‐
cerning selector lever positions or shifting operations are trans‐
ferred to the gearbox control unit via a separate control unit in the
selector mechanism and the CAN data bus. That is, gears are
shifted without any mechanical cables being involved. Only for
selector lever position “P” the parking lock is engaged mechani‐
cally via the selector lever cable.
Gear change point variations for gradients
An additional gear change map automatically selects gear
changes for gradients dependent upon accelerator pedal position
and driving speed.
• Gear change map for extreme uphill stretches is matched to
engine output.
• Gear change map for extreme downhill gradients is matched
to the braking efficiency of the engine.
• If a gear is selected directly via the Tiptronic system, it is also
possible to use the braking effect of the engine in a specific
gear, e.g. when driving down a slope with a trailer attached.
3.2 Rules for cleanliness

♦ First thoroughly clean connecting points and surrounding
areas and then loosen bolts.
♦ Seal open lines and connections immediately using clean
plugs or sealing caps from engine bung set - VAS 6122- .
♦ Place removed parts on a clean surface and cover them to
prevent them from getting dirty. Use sheeting and paper for
this purpose. Use lint-free cloths only.
♦ Make sure that no dirt can enter an »open« gearbox.
♦ Install only clean parts; do not remove Genuine parts from
packaging until immediately before installing.
3. Repair instructions 5
♦ If repair work cannot be performed immediately, cover opened

parts carefully.
♦ Protect disconnected electrical connectors from dirt and water,
and only reconnect them in dry condition.
3.3 General repair instructions

To ensure flawless and successful gearbox repairs, the greatest
care and cleanliness as well as the use of good and proper tools
are essential. Also note the basic rules on safety when performing
repair procedures.
A number of general notes on the individual repair procedures,
which can otherwise be found in the relevant sections of the man‐
ual, are summarised here. They apply for this particular workshop
manual.
Guided Fault Finding, vehicle self-diagnosis and test instruments
♦ Before performing repairs to the gearbox, determine the cause
of the fault as accurately as possible ⇒ Vehicle diagnostic
tester, Guided Fault Finding , Vehicle Self-Diagnosis
or Test Instruments .
Special tool
For a complete list of special tools used in this workshop manual,
see ⇒ "Workshop equipment and special tools" .
Gearbox
Always make sure that no dirt can enter an »open« gearbox. In
particular, dirt entering an »exposed« mechatronic unit for dual
clutch gearbox - J743- and/or oil pump can lead to gearbox failure.
♦ If gearbox covers have been unbolted or gearbox has no fluid,
do not run engine or tow vehicle.
♦ First thoroughly clean connecting points and surrounding
areas and then loosen bolts.
♦ When installing the gearbox, ensure that dowel sleeves be‐
tween the engine and gearbox are correctly located.
Locking devices
♦ Do not overstretch retaining rings.
♦ Always renew retaining rings which have been damaged or
overstretched.
♦ Retaining rings must locate properly in grooves.
Dual clutch gearbox oil
The oil quality is of critical importance for the function of the gear‐
box.
Shake oil bottle before opening.
Do not mix additives in oil. Do not fill any other oil.
Oil which has been drained out cannot be filled again.

Oil drain and inspection plug

A plastic overflow pipe (with 8 mm hexagon socket head) is lo‐
cated behind this plug -arrow-. Its length determines the oil level
in the gearbox.
3.4 Gaskets and seals

♦ Renew O-rings, seals and gaskets.
♦ After removing gaskets and seals, always inspect contact sur‐
face of housing or shaft for burrs resulting from removal or for
other signs of damage.
♦ Before installing seals, lightly oil outer diameter and half-fill
space between sealing lips -arrow- with sealing grease -
G 052 128 A1- .
♦ The open side of the oil seals faces toward the side with fluid
filling.
♦ Only use dual clutch gearbox oil. Other lubricants will cause
problems in function.
♦ Coat O-rings with dual clutch gearbox oil to prevent pinching
of rings during assembly.
♦ After renewing gaskets, O-rings and seals, check oil level in
gearbox and top up if necessary ⇒ page 164 .
3.5 Nuts and bolts

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

Take account of the gearbox code if spare parts are required for
a repair.
Dual clutch gearbox 0DL, all-wheel drive
Codes QAX, RCG, SDR, QBB, SDM
TJG, TJM
Engine 2.0 l - 176 kW TDI 2.0 l - 162 kW TSI
4.1.2 Tiguan 2016 ►

a repair.
Codes QAY, QAY, QBB, TAH, QBA,
RPN, SDK, RPL, TFQ, RPM,
SDK, RPN, RPP, TNZ, SDL,
TFR TFR, SDN, TUS TFS,
TNY TAH, TJL
TFQ,
TUR
Engine 2.0 l - 2.0 l - 2.0 l - 2.0 l - 2.0 l -
105, 110 130, 132, 169 kW 176 kW
kW TDI 140 162 kW TSI TDI
kW TDI TSI
Dual clutch gearbox 0DL, front-wheel drive

Codes QAZ, RPK, SDS,
TFU
Engine 2.0 l - 110 kW TDI
4.1.3 Arteon 2018 ►

a repair.
Codes RWU, TFT, TJM
Engine 2.0 l - 176 kW TDI
4.1.4 Passat 2019 ►, Passat estate 2019 ►

a repair.
Codes TJM SDM
Engine 2.0 l - 176 kW TDI 2.0 l - 162 kW TSI
4.2 Capacities
Capacity Dual clutch gearbox 0DL
Initial filling 7.0 l ± 0.1 l
8 Rep. gr.00 - Technical data Volkswagen Technical Site: http://vwts.ru http://vwts.info

Capacity Dual clutch gearbox 0DL

Changing approx. 5.5 litres
♦ Change interval: ⇒ Maintenance manual and/
or ⇒ service tables “ELSA”
Lubricant Dual clutch gearbox oil

The oil is available as a replacement part; part no. ⇒ Electronic
parts catalogue (ETKA) .
Further information in the part number designates the container
size.
Capacity Front bevel box

Capacity of bevel box 0A6 0.9 l
⇒ page 34
Capacity of bevel box 0CP 0.75 l
⇒ page 34
Changing Filled for life, no change
Lubricant Gear oil
The oil is available as a replacement part; part no. ⇒ Electronic
parts catalogue (ETKA) .
Further information in the part number designates the container
size.
4. Technical data 9
5 Electrical components
5.1 Overview of fitting locations - electrical components
1 - Mechatronic unit for dual

clutch gearbox - J743-
❑ Removing and installing
⇒ page 26
2 - Gearbox input speed send‐
er - G182- and oil temperature
sender in multi-plate clutch -
G509-
❑ Both senders are com‐
bined in one component
and can be renewed to‐
gether only.
⇒ page 32
❑ Before removal of the
sender, the mechatronic
unit for dual clutch gear‐
box - J743- must be re‐
moved ⇒ page 26 .
❑ Discontinued as of gear‐
box date 06/15
3 - Selector lever - E313-
❑ With selector lever sen‐
sors control unit - J587- ,
selector lever lock sole‐
noid - N110- and selec‐
tor lever locked in posi‐
tion P switch - F319-
❑ The components are in‐
tegrated into the printed
circuit of the selector
mechanism and cannot
be renewed separately
❑ Checking ⇒ vehicle di‐
agnostic tester
selector mechanism ⇒ page 72

30 – Clutch
1 Clutch
⇒ “1.1 Assembly overview - dual clutch”, page 11
⇒ “1.2 Removing and installing clutch end cover”, page 12
⇒ “1.3 Removing dual clutch”, page 15
⇒ “1.4 Installing dual clutch”, page 18
1.1 Assembly overview - dual clutch

Replacement parts
1 - Retaining ring for dual

clutch end cover
❑ Renew after removal
2 - Retaining ring for dual
clutch
3 - Retaining ring for drive plate
4 - Dual clutch
Caution
The
♦ drive plate has to re‐
main engaged between
the teeth of the outer
plate carrier.
If♦the drive plate de‐
taches, the plates in the
dual clutch can shift. It
may then not be possible
to adjust the clutch cor‐
rectly when it is installed.
5 - Shims
❑ 10 spacer rings which
have different »thick‐
nesses«. They are sized
in 0.05 mm increments.
❑ Thickness of spacer ring
must be determined
when installing dual
clutch.
6 - Dual clutch end cover
1. Clutch 11
Caution
♦ This figure is intended only to provide an overview of the

components. The dual clutch must not be dismantled be‐
cause all the plates have been balanced relative to each
other.
♦ If the drive plate is detached, the plates in the dual clutch
can shift, and consequently it may not be possible to adjust
the clutch correctly when it is installed.
1.2 Removing and installing clutch end cov‐

er
Special tools and workshop equipment required
♦ Clean assembly sleeve - T10459- before using. Do not use a
scratched sleeve.
Brief description
The cover is held in its seat by a retaining ring. After the retaining
ring has been removed, the cover can be levered out of its seat.
Cover and retaining ring must always be renewed. Never install
a new cover with a hammer and never oil the centre seal or touch
it with a hand! However, if this should happen, the cover is certain
to leak!
Removing
The gearbox must be removed for work on cover.
– Drain gear oil ⇒ page 166 .
– Remove gearbox ⇒ page 90 .
– Secure gearbox to assembly stand ⇒ page 159 .
Often, doubts arise as to whether the filter must be renewed or
not.
Note
It is not always necessary to change the oil filter ⇒ page 161 .
12 Rep. gr.30 - Clutch

– Remove filter if necessary ⇒ page 161 .
– Lever out retaining ring -2- of clutch end cover using screw‐
driver -1- -arrow- and remove.
Cover can be levered out with a screwdriver.
Note
The removed cover and retaining may not be installed again.
Install only a »new« cover.
Installing
Caution
Cover and retaining ring must always be renewed.

Never grasp a new cover in centre seal. The centre hole of the
cover must not be touched, oiled or brought into contact with
other materials. Leaks will result.
Never install new covers with a hammer!
1. Clutch 13
– Only handle cover as shown -in this picture-.
Note
There must be no stickers on the inside of the cover. If stickers

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

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

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

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

-as shown in this figure-. This will bring the sealing lip into in‐
stallation position.
– Remove sleeve upwards out of cover and set sleeve on end
of clutch shaft.
– Moisten outer seal of cover with oil.
Caution
Moisten only the outer seal of the cover with oil. Oiling the inner
seal will always cause leaks.

– Guide cover horizontally over sleeve and press evenly onto its
seat.
Caution
Work carefully. Any sort of blow to the cover is certain to cause

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

-screwdriver- until »new« retaining ring can be installed.
– Install new retaining ring.
– Do not remove bush until retaining ring is installed.

– Installing gearbox ⇒ page 148
– Top up gear oil ⇒ page 166 .
WARNING
Do not start engine if there is no oil in gearbox.
1.3 Removing dual clutch

♦ Hooks - 3438- , qty. 2
1. Clutch 15
♦ Puller - T10055-
♦ Puller - T10525-
Brief description
• The axial play of the clutch is readjusted during installation
procedure.
• To remove or install clutch, gearbox must be securely attached
to an assembly stand in vertical position ⇒ page 159 . Only
this way is it possible later to adjust axial play of the clutch
without error.
Removing
– Remove clutch end cover ⇒ page 12 .
Important! Installation location of drive plate
– Check that marking on drive plate -arrow- aligns with the mark‐
ing on the outer plate carrier.
If there is no marking:
– Mark installation position of drive plate relative to periphery of
outer plate carrier with permanent marker, as shown in illus‐
tration.
• During installation, drive plate must always be repositioned at
marked position.
Note
The retaining ring is renewed together with the clutch. If the clutch
which is removed is reinstalled, the securing ring is to be used
again as well.

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

-1- -arrow-.
– Apply puller - T10525- together with puller - T10055- on

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

to measure axial clearance.
1. Clutch 17
– Remove shim -arrow-.
Caution
Carefully remove the dual clutch. Take care that no parts fall
out. Therefore, do not turn the clutch over!
– Engage 2 hooks - 3438- on opposite sides of clutch -arrow-.
– Remove dual clutch using hooks - 3438- .
1.4 Installing dual clutch

♦ Universal dial gauge holder - VW 387-

♦ Dial gauge - VAS 6079-
♦ Retaining pins - T10524-
♦ Drift sleeve - 40-21-
Caution
♦ The drive plate has to remain engaged between the teeth

of the outer plate carrier.
♦ If the drive plate detaches, the plates in the dual clutch can
shift. It may then not be possible to adjust the clutch cor‐
rectly when it is installed.
♦ Do not lift (not even slightly) or remove plate carrier! The
plates could turn.
Brief description
• To remove or install the clutch, the gearbox must be securely
attached to an assembly stand in vertical position.
• The large plate carrier goes through all plates inside the clutch.
It must not slip out of the lowest plate.
1. Clutch 19
Installing
– Take great care when removing the dual clutch from its pack‐
age.
– Turn piston rings by hand. They must move freely and must
not bind.
– Ensure that piston rings -1-, -2-, -3- and -4- are seated cor‐
rectly. The ring butts -arrows- of piston rings -1- and -3- should
align.
– The ring butts -arrows- of piston rings -2- and -4- should align
and be offset 180° to the ring butts of piston rings -1- and -3-.
Important! Position of drive plate

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

The retaining pin - T10524- should be held by a second mechanic
while the dual clutch is being inserted.

– Carefully insert -dual clutch-, ensuring it does not fall.

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

retaining pin - T10524- .
Note
♦ The retaining pin remains inserted until the clutch end cover
is installed.
♦ The dual clutch must now not be rotated any more, as this can
shift the position of the retaining pin - T10524- .
– Lever out retaining ring -2- of drive plate using screwdriver

-1- -arrow-.
Note
This retaining ring will be used again. Do not dispose of it.
1. Clutch 21
– Apply puller - T10525- together with puller - T10055- on

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

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

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

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

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

– Set -dial gauge- to 0 with preload.

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

save value “A” until the last measurement has been performed.
Second measurement
– Set tip of dial gauge -on hub of large plate carrier-.
Note
Tip must not sit on retaining ring.
– Set -dial gauge- to 0 with preload again.

– Lift dual clutch with force to stop and note measurement.
– Call this value “B”.
Now calculate which shim must be fitted:
– Use this formula:
Value “B” minus value “A” minus 0.11 = thickness of shim to
be fitted.
– Note result.
The shims are sized in 0.05 mm increments.
– Measure the shims and determine which one is closest to the
result.
WARNING
Always use the next-largest shim, never the next-smallest.
Example:
Calculated dimension for shim New shim
1.28 mm 1.3 mm
1.26 mm 1.3 mm
– Remove old retaining ring -arrow-.
Note
Do not dispose of ring yet; it will be needed once more.
1. Clutch 23
– Fit calculated shim.

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

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

– Fit drive plate into dual clutch.

• When installing, check if marking on drive plate is aligned with
marking on outer plate carrier -arrows-. If the markings were
subsequently make, align these.
– A second mechanic must hold retaining pin - T10524- in its
place and press outwards slightly.
– Carefully drive the drive plate onto its seat using press tool -
40-21- and a plastic hammer.
– Install drive plate retaining ring.
– Starting at the opening, press retaining ring in clockwise di‐
rection into its fitting position.
• The retaining ring must be fully engaged.
– Use screwdriver to check that retaining ring is correctly seated
and engaged.
– Now remove retaining pin - T10524- from between dual clutch
and housing.
– Install clutch end cover ⇒ page 12 .
1. Clutch 25
34 – Controls, housing
1 Mechatronic unit
⇒ “1.1 Removing and installing mechatronic unit for dual clutch
gearbox J743 (gearbox installed)”, page 26
⇒ “1.2 Removing and installing gearbox input speed sender G182
and oil temperature sender in multi-plate clutch G509 up to gear‐
box date 05/15”, page 32
1.1 Removing and installing mechatronic

unit for dual clutch gearbox - J743-
(gearbox installed)
♦ Up to gearbox date 05/15 release tool - T10465-
♦ Torque wrench - V.A.G 1331-
Always make sure that no dirt can enter an »open« gearbox.

In particular, dirt entering an »exposed« mechatronic unit for dual
clutch gearbox - J743- can lead to gearbox failure.
Please also refer to the notes on the oil filter change regarding
»dirty oil« ⇒ page 161 .
Remove mechatronic unit.
– Move selector lever to position “P”.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
26 Rep. gr.34 - Controls, housing

Note
It is possible that parts having nothing to do with the mechatronic

unit must be removed. This depends on the vehicle's equipment.
This will create enough space to remove the mechatronic unit.
Vehicles with petrol engine

– Remove connecting hose between charge air cooler and
charge air pipe ⇒ Rep. gr. 21 ; Charge air system; Assembly
overview - charge air system .
Continued for all vehicles
– Remove electrical wiring and retainer from front of sump

-arrows- (2 x M6 nuts).
– Raise wiring in area of sump and secure it.
– Place used oil collection and extraction unit - V.A.G 1782- be‐
low gearbox.
– Drain oil ⇒ page 166 .
– Remove securing clip -3-.

– Unscrew bolts -1- diagonally and remove.
– Remove cover -2- with seal.
Note
Always renew bolts, securing clips and the cover with seal.
1. Mechatronic unit 27
Before touching mechatronic unit, touch an earthed object again.
To gearbox date 05/15

– Release connector -1- of gearbox input speed sender - G182-
and oil temperature sender in multi-plate clutch - G509- using
release tool - T10465- .
Continued for all:
– Remove bolts -arrows- diagonally.

All 9 bolts have same length and are not allowed to be reused.

– Remove mechatronic unit -1- carefully.
Caution
• Lift or put down mechatronic unit only on housing and on

solenoid valves.
Lay mechatronic unit to side properly.

– Put down mechatronic unit so that sensors -arrows- are point‐
ing upwards.
Install mechatronic unit.
Install in reverse order of removal. During this procedure, observe
the following:
WARNING
Before installing the mechatronic unit, clean the sealing sur‐

face on the gearbox housing thoroughly without using cleaning
agents. Always make sure that no dirt can get into the inside.

– Before installation, check that »sender« -1- is installed
⇒ page 32 .
Continued for all:
Before touching mechatronic unit, touch an earthed object again.
Caution
• Lift or put down mechatronic unit only on housing and on

solenoid valves.
– Carefully insert mechatronic unit -1- into gearbox.

– Screw in new bolts -arrows- diagonally until finger-tight.
– Tighten bolts in specified sequence to 8 Nm + 45°.


– Push on connector -1- and engage.
– After this, check that fastener -2- is not damaged.
Caution
• Work with great care. The fastener of the connector -2-

can break. If this has happened, the connector will no
longer hold and the damaged part, e.g. mechatronic unit
for dual clutch gearbox - J743- must be renewed.
Continued for all:
– Check seal -arrow- for damage. Renew seal if defective.

A new mechatronic unit already has a new oil seal.
– Moisten seal with oil.
– Set new cover with seal -2- in place and tighten with new bolts
-1- diagonally in several stages to 10 Nm + 45°.
– Install new securing clip -3-.
– Attach wire retainer to cover and tighten nuts to 10 Nm.
– Push on connector for mechatronic unit for dual clutch gearbox
- J743- and engage lock by turning.
– Do not start engine!

– Fill with oil ⇒ page 166 .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Assembly overview – noise insula‐
tion .
– Conduct basic adjustment of mechatronic unit for dual clutch
gearbox - J743- .
1.2 Removing and installing gearbox input

speed sender - G182- and oil tempera‐
ture sender in multi-plate clutch - G509-
up to gearbox date 05/15
Note
♦ As of gearbox date 06/15, the gearbox input speed sender -

G182- and the oil temperature sender in multi-plate clutch -
G509- have been discontinued.
♦ If a sender is fitted, a sender must be reinstalled after it has
been removed.
♦ The following procedure applies only to gearboxes in which a
sender is fitted.
Brief description
Both senders are combined in one component and can be re‐
newed together only. They are in the gearbox near the multi-
clutch. Before removal, the mechatronic unit for dual clutch
gearbox - J743- must be removed.
Removing
– Remove mechatronic unit for dual clutch gearbox - J743-
⇒ page 26 .
Do not pull on line!
– Unscrew and remove bolt -2- and pull out sender -1-.
Installing
the following:
Reinstall »old« sender only if:
• The sender has no defect
• The cable was not pulled on when it was removed
– Moisten sender with dual clutch gearbox oil and install.

– Tighten bolt -2- to 10 Nm.

– Install mechatronic unit for dual clutch gearbox - J743-
⇒ page 26 .
2 Bevel box
⇒ “2.1 Distinguishing between different types of bevel boxes”,
page 34
⇒ “2.2 Removing and installing bevel box”, page 35
⇒ “2.3 Detaching bevel box from gearbox - gearbox removed”,
page 57
2.1 Distinguishing between different types

of bevel boxes
The bevel box installed in the vehicle could be “0A6” or “0CP”.
Bevel boxes can be identified by means of the following:
Distinguishing feature with bevel box installed:
Determine version of bevel box by recess -arrow- in right area of
subframe.
Remove following components if necessary:
– Noise insulation ⇒ General body repairs, exterior; Rep. gr.
66 ; Noise insulation .
– Centre underbody cladding ⇒ General body repairs, exterior;
Rep. gr. 66 ; Underbody cladding; Removing and installing
underbody cladding .
Area denoted by -arrow- is marked with “0A6” or “0CP”.
Additional distinguishing feature with bevel box removed:

Output flange on bevel box “0A6” is secured with a nut -A- ⇒ As‐
sembly overview - bevel box, “0A6” ⇒ page 189 .
Disregard -B- and -arrows-.

Output flange on bevel box “0CP” is secured with a retaining ring

-A- ⇒ Assembly overview - bevel box, “0CP” ⇒ page 191 .
Located behind retaining ring -A- is a washer -B-.
2.2 Removing and installing bevel box

⇒ “2.2.1 Removing and installing bevel box, Passat 2015 ►, Pas‐
sat estate 2015 ►, Tiguan 2016 ►, Arteon 2018 ►, Passat 2019 ►,
Passat estate 2019 ►, vehicles with 2.0 l - 176 kW TDI with bitur‐
bo”, page 35
⇒ “2.2.2 Removing and installing bevel box, Passat 2015 ►, Pas‐
sat estate 2015 ►, Passat estate 2019 ►, vehicles with petrol
engine”, page 40
⇒ “2.2.3 Removing and installing bevel box, Tiguan 2016 ►”, page
48
2.2.1 Removing and installing bevel box, Passat 2015 ►, Passat estate 2015 ►,
Tiguan 2016 ►, Arteon 2018 ►, Passat 2019 ►, Passat estate 2019 ►, ve‐
hicles with 2.0 l - 176 kW TDI with biturbo
2. Bevel box 35
Special tools and workshop

equipment required
♦ Multi-purpose tool - VW 771-

♦ Hexagon key extension, 8 mm - 3247-
♦ Supplementary set for engine and gearbox support - VW 540/1
B-
♦ Puller - T 10472-
Removing
– Raise vehicle. All 4 supports of lifting platform must be at same
height.
Note
After loosening centre bolt, do not lower vehicle to ground again.

The right drive shaft will be removed in a later step.

– Do not loosen the front flange bolt -arrow- more than 90° while
the vehicle is still standing on its wheels, or the wheel bearing
will be damaged. ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shaft; Removing and installing drive shaft .
Note
So that the propshaft can be turned later in order to loosen it:
– Move selector lever to »N« position.

– Remove exhaust gas recirculation cooler ⇒ Rep. gr. 26 ; Ex‐
haust gas recirculation; Removing and installing exhaust gas
recirculation cooler .
The engine support - T10533- -A- remains in the forward position

after the cooler has been removed. This makes it easier to remove
the bevel box later.
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .
– Unscrew bolts -A and B-, and remove gearbox carrier -1- for
bevel box.
– Remove upper securing bolts -arrows- securing bevel box to

gearbox.
2. Bevel box 37
– Loosen lower securing bolts securing bevel box to gearbox

and unscrew only as far as dimension -a-.
Dimension -a- = 15 mm.
This prevents the bevel box from falling down immediately when
loosened using multi-purpose tool - VW 771- .
– Fit puller - T 10472- to bevel box.
– Prepare multi-purpose tool - VW 771- with a washer -a- and 2

sleeves from the supplementary set for engine and gearbox
support - VW 540/1 B- as shown in the illustration.
– Bolt multi-purpose tool - VW 771- onto puller - T10472- and

loosen bevel box from gearbox.
– Remove multi-purpose tool - VW 771- and puller - T10472-
from bevel box.

– Unscrew lower securing bolts -arrows- and remove bevel box.

Installing
When installing, note the following:
– Grease splines of differential with grease for clutch plate

splines - G 000 100- .
– Install new retaining ring -arrow A- and new O-ring -arrow B-
on right stub shaft.
– Insert bevel box and press against gearbox as far as it will go.
Note
Turn stub shaft if spline position is unfavourable (bevel box cannot

be pressed to stop against gearbox).
– If splines are correctly positioned and shafts are centred, then

bevel box will slide to stop against gearbox.
Caution
To ensure that the retaining ring of the stub shaft engages

properly in the differential bevel gear, strike the face of the
spline stub with a plastic hammer. Do not pull bevel box force‐
fully against gearbox by turning securing bolts. Damage to
gearbox or bevel box could result.
– Screw on bevel box with new bolts -arrows- until finger-tight,

then tighten. Specified torque: ⇒ page 89 .
2. Bevel box 39
– Unbolt gearbox carrier for bevel box. Observe installation lo‐

cation and tightening sequence of bolts ⇒ page 89 .
– Install exhaust gas recirculation cooler ⇒ Rep. gr. 26 ; Ex‐
haust gas recirculation system; Removing and installing ex‐
haust gas recirculation cooler .
– Install right drive shaft ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Drive shaft; Removing and installing drive shaft .
– Check gear oil in bevel box ⇒ page 172 .
– Following installation, check oil level in gearbox
⇒ page 164 .
gr. 66 ; Noise insulation .
Specified torques: ⇒ page 89
2.2.2 Removing and installing bevel box, Passat 2015 ►, Passat estate 2015 ►,
Passat estate 2019 ►, vehicles with petrol engine

equipment required



B-
♦ Puller - T 10472-
♦ Counter-hold tool - T10172A-
♦ Engine support - T10533-
Removing
height.
Note

Note

– Remove noise insulation below engine and gearbox. ⇒ Gen‐
eral body repairs, exterior; Rep. gr. 66 ; Noise insulation
2. Bevel box 41
– Disconnect connector -1- from oil level and oil temperature

sender - G266- .
– Remove drive shaft heat shield -1-, if present, from bevel box
(-arrows-) ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive
shaft .
Caution
Risk of damage to flexible joint.

♦ Observe ⇒ Rep. gr. 26 ; Emission control; Assembly
overview - emission control .
– Remove front exhaust system from engine, raise it and tie it in

place ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Assembly
overview - silencer .
If fitted, remove heat shield for propshaft.
– Unscrew bolts -A- and -B- from bevel box, and remove heat
shield -1-.
– Mark position of propshaft with flexible coupling relative to

output shaft of bevel box -arrows-.

– Unbolt front propshaft from bevel box -arrows-.
– If necessary, counterhold at rear final drive when loosening or

tightening propshaft.
Note
To loosen »next« bolt, turn propshaft further by turning rear

wheels at same time.
– Unscrew pendulum support bolts -1- from gearbox.

– Place a cloth on subframe to avoid damaging paint of prop‐
shaft when it is placed on subframe.
– Push font propshaft back to stop. Make sure not to damage

seal -arrow- in centring bush.
2. Bevel box 43
– Guide propshaft upwards into tunnel, and use a suitable piece

of wood to support it on subframe.
– Set up engine support - T10533- as shown in figure and tighten

bolts hand-tight.
• -A- thin end
• -B- thick end
Bolt -3- = original pendulum support bolt
– Screw an M 8 x 30 mm bolt -1- with a washer -2- into threaded
hole for noise insulation.
It may be necessary to push the gearbox forwards slightly in order
to attach the engine support - T10533- .
– Force engine/gearbox as far forwards as possible by turning
spindle of engine support - T10533- . Avoid collisions between
components and radiator cowl.
– Unbolt gearbox carrier.
– Unscrew bolts -1- and -2-, and remove carrier from bevel box.

gearbox.




from bevel box.
2. Bevel box 45

Installing

splines - G 000 100- .
Note


Caution


– Install gearbox carrier. Observe installation location and tight‐
ening sequence of bolts ⇒ page 89 .

– Mount drive shaft heat shield -1-, if present, on bevel box

shaft .
– Fit propshaft on bevel box.
Note
When removing and installing the bevel box, do not damage the
seal in the propshaft flange -arrow-. Renew propshaft if damaged.
– Join bevel box and propshaft by turning spindle of engine sup‐

port - T10533- .
– Remove engine support - T10533- .
– Bolt propshaft to bevel box -arrows- ⇒ Rep. gr. 39 ; Propshaft;

Removing and installing propshaft .
– If present, install heat shield for propshaft.
2. Bevel box 47
Version 1:
Version 2:
– Secure pendulum support to gearbox using new bolts -1-.

Specified torque: ⇒ Rep. gr. 10 ; Assembly mountings; As‐
sembly overview - assembly mountings .
– Install parts of exhaust system ⇒ Rep. gr. 26 ; Exhaust pipes/
silencers .
⇒ page 164 .
2.2.3 Removing and installing bevel box, Ti‐

guan 2016 ►
Note
The following procedure does not apply to vehicles with bitur‐
bocharger.
Removing and installing bevel box - vehicles with 2.0 l - 176 kW

TDI engine and bi-turbocharger ⇒ page 35


equipment required

B-
♦ Puller - T 10472-
2. Bevel box 49
♦ Engine support - T10533-
Removing
height.
Note

Note

– Remove noise insulation below engine and gearbox. ⇒ Gen‐
eral body repairs, exterior; Rep. gr. 66 ; Noise insulation
Vehicles with petrol engine:
– Remove connecting hose between charge air cooler and

charge air pipe ⇒ Rep. gr. 21 ; Charge air system; Assembly
Vehicles with diesel engine:

– Separate connector -1-.

– Unscrew bolt -2- and push auxiliary pump for heating - V488-
to right side. Do not disconnect any lines ⇒ Rep. gr. 19 ;
Coolant pump, regulation of cooling system; Assembly over‐
view - electric coolant pump .
Continued for all vehicles:

sender - G266- .
shaft .
Caution
Risk of damage to flexible joint.

♦ Observe ⇒ Rep. gr. 26 ; Emission control; Assembly
overview - emission control .
– Remove front exhaust system from engine, raise it and tie it in

place ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Assembly
overview - silencer .
If fitted, remove heat shield for propshaft.
– Unscrew bolts -A- and -B- from bevel box, and remove heat
shield -1-.
2. Bevel box 51

– Unbolt front propshaft from bevel box -arrows-.

Note
To loosen »next« bolt, turn propshaft further by turning rear

wheels at same time.
– Unscrew pendulum support bolts -1- from gearbox.

– Place a cloth on subframe to avoid damaging paint of prop‐
shaft when it is placed on subframe.

– Push font propshaft back to stop. Make sure not to damage

seal -arrow- in centring bush.
– Place front propshaft on heat shield or on subframe as appro‐
priate.
– Set up engine support - T10533- as shown in figure and tighten

bolts hand-tight.
• -A- thin end
• -B- thick end
Bolt -3- = original pendulum support bolt
– Screw an M 8 x 30 mm bolt -1- with a washer -2- into threaded
hole for noise insulation.
It may be necessary to push the gearbox forwards slightly in order
to attach the engine support - T10533- .
– Force engine/gearbox as far forwards as possible by turning
spindle of engine support - T10533- . Avoid collisions between
components and radiator cowl.
– Unbolt gearbox carrier for bevel box.
Diesel engine:
– Unscrew bolts -A and B-, and remove gearbox carrier -1- for
bevel box.
Petrol engine:
– Unscrew bolts -1- and -2-, and remove carrier from bevel box.
Continued for all:
2. Bevel box 53

gearbox.




from bevel box.

Installing

splines - G 000 100- .
Note


Caution

2. Bevel box 55

– Unbolt gearbox carrier for bevel box. Observe installation lo‐
cation and tightening sequence of bolts ⇒ page 89 .
– Mount drive shaft heat shield -1-, if present, on bevel box

shaft .
– Fit propshaft on bevel box.
Note
When removing and installing the bevel box, do not damage the
seal in the propshaft flange -arrow-. Renew propshaft if damaged.
– Join bevel box and propshaft by turning spindle of engine sup‐

port - T10533- . Take note of seal in propshaft flange when
doing this.
– Remove engine support - T10533- .

– Bolt propshaft to bevel box -arrows- ⇒ Rep. gr. 39 ; Propshaft;

Removing and installing propshaft .
– If present, install heat shield for propshaft.
– Secure pendulum support to gearbox using new bolts -1-.

Specified torque: ⇒ Rep. gr. 10 ; Assembly mountings; As‐
sembly overview - assembly mountings .
– Install parts of exhaust system ⇒ Rep. gr. 26 ; Exhaust pipes/
silencers .
Continue installation in reverse order of removal.
⇒ page 164 .
2.3 Detaching bevel box from gearbox -

gearbox removed
2. Bevel box 57
♦ Puller - T 10472-
Removing
– Remove gearbox with bevel box ⇒ page 90 .
– Secure gearbox with bevel box to assembly stand
⇒ page 159 .
In the following illustrations the bevel box is shown in installed
condition.
gearbox.


– Bolt multi-purpose tool - VW 771- onto puller T10472 and


Installing
2. Bevel box 59

splines - G 000 100- .
– Insert bevel box and press against gearbox.
Note


bevel box will slide against contact surface on gearbox.
Caution
Retaining ring on stub shaft must engage correctly in differen‐

tial bevel gear. If retaining ring is not engaged, there is a risk
that stub shaft might move outwards.
Also, bevel box is not allowed to be bolted onto gearbox force‐
fully. Damage to gearbox or bevel box could result in both
cases.
– To ensure that the retaining ring engages properly in the dif‐

ferential bevel gear, strike the face of the spline stub several
times with a plastic hammer (weight 1000 - 2000 g).

– Installing gearbox ⇒ page 148
– After installing gearbox, check oil level and top up
⇒ page 164 .

3 Selector mechanism
⇒ “3.1 Assembly overview - selector mechanism”, page 61
⇒ “3.2 Emergency release from position P”, page 64
⇒ “3.3 Removing and installing selector lever handle”,
page 65
⇒ “3.4 Moving push-button in the handle to installation position”,
page 70
⇒ “3.5 Removing and installing selector mechanism”, page 72
⇒ “3.6 Removing and installing gear selector cable”, page 79
⇒ “3.7 Checking selector mechanism”, page 84
⇒ “3.8 Checking and adjusting selector lever cable”, page 84
⇒ “3.9 Renewing selector shaft seal”, page 86
3.1 Assembly overview - selector mecha‐

nism
⇒ “3.1.1 Assembly overview – selector mechanism, Passat
2015 ►, Passat estate 2015 ►, Arteon 2018 ►, Passat 2019 ►,
Passat estate 2019 ►”, page 61
⇒ “3.1.2 Assembly overview- selector mechanism, Tiguan 2016
►”, page 63
3.1.1 Assembly overview – selector mechanism, Passat 2015 ►, Passat estate

2015 ►, Arteon 2018 ►, Passat 2019 ►, Passat estate 2019 ►
3. Selector mechanism 61
1 - Handle with selector cover

❑ Do not remove handle
without reason. For
emergency release, on‐
ly the cover needs to be
unclipped ⇒ page 64 .
⇒ page 65
2 - Bolt
❑ Qty. 4
❑ 8 Nm
3 - Selector mechanism
❑ With integrated selector
lever sensor control unit
- J587- with selector lev‐
er - E313- , Tiptronic
switch - F189- , switch
for selector lever locked
in P - F319- and selector
lever lock solenoid -
N110-
⇒ page 72
4 - Selector lever cable
❑ Selector lever cable is
not greased
⇒ page 79
❑ Checking ⇒ page 84
❑ Adjusting ⇒ page 84
5 - Securing clip
6 - Hexagon flange nut
❑ Qty. 4
❑ 8 Nm
7 - Selector housing
8 - Cover
9 - Bolt
❑ For selector cable support bracket to gearbox
❑ Qty. 2
❑ 20 Nm +90°
10 - Gearbox
11 - Bolt
❑ Adjuster screw for selector lever cable
❑ 13 Nm

3.1.2 Assembly overview- selector mechanism, Tiguan 2016 ►
1 - Handle with selector cover

⇒ page 65
2 - Selector mechanism
❑ With integrated selector
lever sensor control unit
- J587- with selector lev‐
er - E313- , Tiptronic
switch - F189- , switch
for selector lever locked
in P - F319- and selector
lever lock solenoid -
N110-
⇒ page 72
3 - Bolt
❑ Qty. 4
❑ 8 Nm
4 - Plug
5 - Hexagon flange nut
❑ Qty. 4
❑ 8 Nm
6 - Selector housing
7 - Gearbox
8 - Bolt
❑ Always renew after re‐
moving.
❑ For selector cable sup‐
port bracket to gearbox
❑ Qty. 2
❑ 20 Nm +90°
9 - Bolt
❑ Adjuster screw for selector lever cable
❑ 13 Nm
10 - Securing clip
❑ Always renew after removing.
❑ Installation position: offset side points forwards towards front end.
11 - Selector lever cable
❑ Selector lever cable is not greased
❑ Removing and installing ⇒ page 81
❑ Checking and adjusting ⇒ page 84
3.2 Emergency release from position P

⇒ “3.2.1 Manual release mechanism from position P, Passat 2015
►, Passat estate 2015 ►, Arteon 2018 ►, Passat 2019 ►, Passat
estate 2019 ►”, page 64
⇒ “3.2.2 Emergency release from position P, Tiguan 2016 ►”,
page 64
3.2.1 Manual release mechanism from posi‐

tion P, Passat 2015 ►, Passat estate
2015 ►, Arteon 2018 ►, Passat 2019 ►,
Passat estate 2019 ►
Do not remove handle
– Depress brake pedal or set handbrake.
– Open lid of storage compartment.
– Grasp under selector lever cover with one hand, and unclip
cover by pulling it upwards.
– Push selector cover to one side.
– Using a screw driver, from right side, press yellow plastic part
and hold in this position.
Selector lever can now be moved from position »P«.
3.2.2 Emergency release from position P, Ti‐

guan 2016 ►

♦ -T10383/2-
Do not remove handle

– Depress brake pedal or set handbrake.
– Fit wedge - T10383/2- at front between centre console and
selector cover, and lever selector cover off centre console by
carefully pushing wedge downwards.
– Push selector cover to one side.
– Push yellow plastic lever backwards in direction of arrow and

hold in this position.
Selector lever can now be moved from position »P«.
3.3 Removing and installing selector lever

handle
⇒ “3.3.1 Removing and installing selector lever handle, Passat
2015 ►, Passat estate 2015 ►, Arteon 2018 ►, Passat 2019 ►,
Passat estate 2019 ►”, page 65
⇒ “3.3.2 Removing and installing selector lever handle, Tiguan
2016 ►”, page 68
3.3.1 Removing and installing selector lever

handle, Passat 2015 ►, Passat estate
2015 ►, Arteon 2018 ►, Passat 2019 ►,
Passat estate 2019 ►
♦ Hose clip pliers - V.A.G 1275-
Brief description
Handle is removed together with selector cover.
Removing
– Shift selector lever to position “D”.
The push button -arrow- does not need to be pulled out by hand.
Push button engages automatically in installation position when
handle is pulled off.
– Open lid of storage compartment.
– Grasp under selector lever cover with one hand, and unclip
cover by pulling it upwards.
– Separate electrical connector.

– Cut open clamp -arrow- under boot using side cutters.

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

possible to install the handle.
Installing
Install in reverse order of removal, observing the following:
• Selector lever is in position “D”.
Note
♦ There is a danger of the button being pressed into the handle.

Never install a handle with the button pressed in.
♦ Move push-button to installation position ⇒ page 70 .
♦ New handle is supplied with installation guard. Do not remove
guard until just before installing. To remove, pull out
-in direction of arrow-.
– Push on handle with new clamp -arrow- to stop. Do not tighten

clamp yet.
– Press push button after installation.
Note
If not installed correctly, the button remains inserted in the handle

after being pressed. If this happens, pull handle off again and
move push button to installation position again ⇒ page 70 . Then
fit the handle again.
– If the push button returns to its start position when released,

the clamp can be tightened using the hose clip pliers - V.A.G
1275- .
– Connect electrical connector.
– Clip cover in position.

handle, Tiguan 2016 ►
♦ Hose clip pliers - V.A.G 1275-
♦ -T10383/2-
Brief description
Handle is removed together with selector cover.
Removing
– Shift selector lever to position “D”.

The push button -arrow- does not need to be pulled out by hand.
Push button engages automatically in installation position when
handle is pulled off.
– Fit wedge - T10383/2- at front between centre console and

selector cover, and lever selector cover off centre console by
carefully pushing wedge downwards.
– Separate electrical connector.
– Cut open clamp -arrow- under boot using side cutters.

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

possible to install the handle.
Installing
• Selector lever is in position “D”.
Note
♦ There is a danger of the button being pressed into the handle.

Never install a handle with the button pressed in.
♦ Move push-button to installation position ⇒ page 70 .
♦ New handle is supplied with installation guard. Do not remove
guard until just before installing. To remove, pull out
-in direction of arrow-.
– Push on handle with new clamp -arrow- to stop. Do not tighten

clamp yet.
– Press push button after installation.
Note
If not installed correctly, the button remains inserted in the handle

after being pressed. If this happens, pull handle off again and
move push button to installation position again ⇒ page 70 . Then
fit the handle again.
– If the push button returns to its start position when released,

the clamp can be tightened using the hose clip pliers - V.A.G
1275- .
– Connect electrical connector.
– Clip cover in position.
3.4 Moving push-button in the handle to in‐

stallation position
If the button was pressed by mistake, the installation position can
be restored.
There are 2 ways of moving the push-button into the installation
position, »with« and »without« installation guard. Both of them are
described here.

Place handle »with« installation guard in installation position:

When using the installation guard, make sure that it has an eyelet
-arrow- at the front. Other types of installation guard are not suit‐
able.
– Holding down push button, completely push in installation

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

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

anism
⇒ “3.5.1 Removing and installing selector mechanism with selec‐
tor lever cable”, page 72
⇒ “3.5.2 Removing and installing selector mechanism without se‐
lector lever cable, Passat 2015 ►, Passat Estate 2015 ►, Arteon
2018 ►”, page 74
⇒ “3.5.3 Removing and installing selector mechanism without se‐
lector lever cable, Tiguan 2016 ►”, page 76
3.5.1 Removing and installing selector mech‐

anism with selector lever cable
Brief description
In the interior, the centre console must be removed.
The heat shield beneath the vehicle must be removed.
Removing
– Remove selector lever handle ⇒ page 65 .
– Remove centre console with securing bracket ⇒ General body
repairs, interior; Rep. gr. 68 ; Centre console; Assembly over‐
view - centre console .
– Remove footwell air duct ⇒ Heating, air conditioning; Rep. gr.
87 ; Air duct; Assembly overview - air routing and air distribu‐
tion in passenger compartment .
– Separate electrical connector from selector mechanism to ve‐
hicle wiring harness.
– Remove air filter housing.
Passat, Tiguan with diesel engine
– ⇒ Rep. gr. 23 ; Air filter; Removing and installing air filter
housing
Tiguan with petrol engine
housing

Continued for all:

– Pry selector lever cable -arrow- off lever using an open-ended
spanner.
Caution
Locks on selector lever cable break off very easily. If a locking

lug has broken off, complete selector mechanism with selector
lever cable must be renewed.
– Carefully push locking mechanisms of selector lever cable to‐

gether -arrows- and remove selector lever cable upwards out
of cable support bracket.
– Do not bend or kink cable.
– Remove propshaft on all-wheel drive model ⇒ Rep. gr. 39 ;
Propshaft; Removing and installing propshaft .
– Install centre tunnel heat shield below selector mechanism ⇒
General body repairs, exterior; Rep. gr. 66 ; Mouldings/trims/
extensions; Removing and installing floor heat shield .
– If fitted, remove bracket -A-.

– Remove nuts -arrows- inside vehicle.
– Remove selector mechanism -B- together with selector lever
cable and selector housing downwards.
Installing
the following:
Note
♦ Do not bend or kink gear selector cable.

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

repairs, exterior; Rep. gr. 66 ; Mouldings/trims/extensions;
Removing and installing floor heat shield .
– Install propshaft on all-wheel drive model ⇒ Rep. gr. 39 ;
– Install footwell air duct ⇒ Heating, air conditioning; Rep. gr.
87 ; Air duct; Assembly overview - air routing and air distribu‐
tion in passenger compartment .
– Install centre console securing bracket and centre console ⇒
General body repairs, interior; Rep. gr. 68 ; Centre console;
Assembly overview - centre console .
– Install selector lever handle ⇒ page 65 .
– Adjust selector lever cable ⇒ page 84 .
– Check selector mechanism ⇒ page 84 .
– Install air filter housing.
Passat, Tiguan with diesel engine
housing
housing
Specified torques
♦ Selector housing to body
⇒ “3.1 Assembly overview - selector mechanism”, page 61

anism without selector lever cable, Pas‐
sat 2015 ►, Passat Estate 2015 ►,
Arteon 2018 ►
Brief description

Removing
– Remove centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; Centre console; Removing and installing centre con‐
sole .
– Remove centre console vent ⇒ Heating, air conditioning; Rep.
gr. 87 ; Air duct; Assembly overview - air routing and air dis‐
tribution in passenger compartment .
– Remove mounting bracket for centre console ⇒ General body
repairs, interior; Rep. gr. 68 ; Centre console; Removing and
installing centre console .
– Shift selector lever on selector mechanism to position “N”.
– Using a screwdriver lever the cover off from under the selector
mechanism -arrow-.
Note
It is not permissible to reuse the cover. Always renew after re‐

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

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

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

– Remove selector mechanism -B- together with selector hous‐
ing downwards.
Installing
the following:
Note

• Selector lever on selector mechanism must be set to position

“N”.
– Insert cable into selector mechanism, attach to selector lever
and fit new securing clip.
– Install mounting bracket ⇒ General body repairs, interior; Rep.
sole .
– Install centre console vent ⇒ Heating, air conditioning; Rep.
gr. 87 ; Air duct; Assembly overview - air routing and air dis‐
tribution in passenger compartment .
– Install centre console ⇒ General body repairs, interior; Rep.
sole .
Specified torques
♦ Selector housing to body ⇒ page 61

anism without selector lever cable, Ti‐
guan 2016 ►
Brief description
Removing
– Remove centre console ⇒ General body repairs, interior; Rep.
sole .

– If fitted, remove footwell air duct ⇒ Heating, air conditioning;

Rep. gr. 87 ; Air duct; Assembly overview - air routing and air
distribution in passenger compartment .
– If fitted, remove mounting bracket -2-. To do this, unscrew
bolts -1- on right and left.
– Shift selector lever on selector mechanism to position “N”. On‐
ly in this position the selector lever cable can be released.
– Remove plug and securing clip -arrow-.

– Fit a large screwdriver in grooves of locking element and turn

it 90° in direction of arrow.
– Pull selector lever cable out of selector mechanism.

– Remove selector mechanism -B- together with selector hous‐
ing downwards.
Installing
the following:
Note


“N”. Only in this position the selector lever cable can be en‐
gaged.
– Insert selector lever cable into selector mechanism until it is

visible in locking mechanism -arrow-.

– The selector lever cable is properly engaged when the

grooves in the locking element are at right angles to the se‐
lector lever cable.

– Install new securing clip -arrow- and insert plug.

– If previously removed, install mounting bracket -2- ⇒ General

body repairs, interior; Rep. gr. 68 ; Centre console; Removing
and installing centre console .
– If featured, install footwell air duct ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air duct; Assembly overview - air routing and air
distribution in passenger compartment .
– Install centre console ⇒ General body repairs, interior; Rep.
sole .
Specified torques
♦ Selector housing to body ⇒ page 63
3.6 Removing and installing gear selector

cable
⇒ “3.6.1 Removing and installing selector lever cable, Passat
2015 ►, Passat Estate 2015 ►, Arteon 2018 ►”, page 79
⇒ “3.6.2 Removing and installing selector lever cable, Tiguan
2016 ►”, page 81

cable, Passat 2015 ►, Passat Estate
2015 ►, Arteon 2018 ►
Removing
Diesel engine
– Remove air filter housing ⇒ Rep. gr. 23 ; Air filter; Removing
and installing air filter housing
Continued for all:

spanner.
Caution


– Remove parts of ⇒ exhaust system; Rep. gr. 26 .
– Using a screwdriver lever the cover off from under the selector
mechanism -arrow-.
Note
It is not permissible to reuse the cover. Always renew after re‐

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

from the selector lever -arrows-.

– Remove securing clip -arrow-.

– Pull cable out of selector mechanism and remove.
Installing
the following:
Note

♦ Following installation, selector lever cable must be checked
for ease of movement and be adjusted.

“N”.
– Check and adjust selector lever cable ⇒ page 84 .
Diesel engine:
– Install air filter housing ⇒ Rep. gr. 23 ; Air filter; Removing
and installing air filter housing .

cable, Tiguan 2016 ►
Removing
Diesel engine
housing
housing
Continued for all:

spanner.
Caution


– Remove plug and securing clip -arrow-.


– Pull cable out of selector mechanism and remove.
Installing
Note

♦ Ensure that selector lever cable moves freely after installing.

“N”. Only in this position the selector lever cable can be en‐
gaged.

– Insert selector lever cable into selector mechanism until it is

visible in locking mechanism -arrow-.

– The selector lever cable is properly engaged when the

grooves in the locking element are at right angles to the se‐
lector lever cable.
– Install new securing clip -arrow- and insert plug.

– Check and adjust selector lever cable ⇒ page 84 .
Diesel engine
housing
housing
3.7 Checking selector mechanism

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

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

cable

Brief description
Selector lever cable must be removed from gearbox so that its
ease of movement can be checked. Put removed end down so it
does not rub against anything.
Then the selector lever must be moved and after that, the Bowden
cable must be reattached to the gearbox.
Then the selector lever cable must be adjusted.
Do not grease connections of cable!
Always adjust selector lever cable if the following applies:
♦ The selector lever cable has been removed from the gearbox.
♦ The engine and/or gearbox has been removed and installed.
♦ Parts of the assembly mounting have been removed and in‐
stalled.
♦ The cable itself or the selector mechanism has been removed
and installed.
♦ The position of the engine and gearbox is shifted, for example
to install it free of tension.
Check
– Switch selector lever to »P« position.
– Remove air filter housing.
Diesel engine
housing
housing
Continued for all:

spanner.
Caution


– Shift selector lever several times from position »P« to »S« and
back to »P«.
• Selector lever must move easily.
– Reinstall cable.
– Then adjust selector lever cable.
Adjusting
– Move selector lever in vehicle to “P” position.
– Selector shaft on gearbox is also in position “P”. To check,
push lever opposite to driving direction to rear stop.
Note
Raise vehicle, to be sure that the gearbox is in “P” (parking lock

engaged). It should not be possible to turn both front wheels to‐
gether in the same direction.
– Loosen bolt -2- of the Bowden cable -1-.

– Gently push knob of selector lever forwards and backwards
but under no circumstances must you shift out of “P”.
– Tighten bolt -2- to 15 Nm.
This completes the adjustment.
Diesel engine
housing
housing
3.9 Renewing selector shaft seal

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

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

– Remove gearbox ⇒ page 90 .
– Remove selector lever cable from gearbox ⇒ page 72 .
– Unscrew securing nut -arrow- and carefully pull gearbox se‐
lector lever -A- off selector shaft.
– Pry seal out -in direction of arrow-.

– Lightly oil outer circumference of new oil seal.
– Fill space between sealing lip and dust lip -arrow- with sealing
grease - G 052 128 A1- .
– Drive new seal in onto limit stop. Do not cant oil seal in the
process.
• Closed side of oil seal -arrow- points towards tube - VW 423- .
– Install gearbox selector lever -A-, and tighten new nut

-arrow-. Specified torque: ⇒ Item 21 (page 155) .
Gearbox selector lever fits on splines in only one position
– Install gearbox ⇒ page 148 .
– Install and adjust selector lever cable on gearbox ⇒ page 84 .

4 Removing and installing gearbox

⇒ “4.1 Specified torques for gearbox”, page 89
⇒ “4.2 Removing gearbox”, page 90
⇒ “4.3 Installing gearbox”, page 148
⇒ “2.3 Detaching bevel box from gearbox - gearbox removed”,
page 57
4.1 Specified torques for gearbox

⇒ “4.1.1 Gearbox carrier to engine and bevel box”, page 89
Item Bolt Nm
1, 2, 3 M12x55 80
• With insert tool
T10179 or
T10509:
»65 Nm«
4 M12×65 80
5, 6, 7 M10x50 40
8 M12×70 80
A Dowel sleeves for centring
Component Nm
Assembly mountings to gearbox (renew bolts after 60 Nm + turn 90° further
each removal)
Earth strap to assembly mounting 25
Heat shield for right drive shaft to bevel box 20
Propshaft to bevel box ⇒ Rep. gr. 39 ; Propshaft; Assembly overview - prop‐
shaft
Bevel box to gearbox 40 Nm + turn 90° further

♦ Renew bolts after re‐
moving.
4.1.1 Gearbox carrier to engine and bevel box

Installation location and tightening sequence:
Diesel engine
Item Bolt
A M10 x 21
B M10 x 45
Sequence Bolts Specified torque

1 -A- and -B- Screw in to contact by hand
2 Tighten -A- 40 Nm
3 Tighten -B- 40 Nm
Petrol engine
4. Removing and installing gearbox 89

Installation location and tightening sequence:

Item Bolt
1 M10 x 45
2 M10 x 21
Sequence Bolts Specified torque

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

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

⇒ “4.2.1 Removing gearbox, Passat 2015 ►, Passat estate 2015
►, Arteon 2018 ►, Passat 2019 ►, Passat estate 2019 ►, vehicles
with 2.0 l - 176 kW TDI with biturbo”, page 90
⇒ “4.2.2 Removing gearbox, Passat 2015 ►, Passat estate 2015
►, Passat estate 2019 ► vehicles with petrol engine”, page 101
⇒ “4.2.3 Removing gearbox, Tiguan 2016 ► vehicles with 2.0 l -
105 kW, 110 kW, 130 kW, 140 kW diesel engine, all-wheel drive”,
page 112
⇒ “4.2.4 Removing gearbox, Tiguan 2016 ►, vehicles with petrol
engine, all-wheel drive”, page 121
⇒ “4.2.5 Removing gearbox, Tiguan 2016 ►, vehicles with diesel
engine, front-wheel drive”, page 131
⇒ “4.2.6 Removing gearbox, Tiguan 2016 ►, vehicles with 2.0 l -
176 kW TDI”, page 139
4.2.1 Removing gearbox, Passat 2015 ►,

Passat estate 2015 ►, Arteon 2018 ►,
Passat 2019 ►, Passat estate 2019 ►,
vehicles with 2.0 l - 176 kW TDI with bi‐
turbo
Brief description
The gearbox is removed downwards together with the bevel box.
»From above«:
The battery, air filter and starter are removed. The coolant hoses
must be clamped off. Support engine and gearbox before left
subframe mounting is unbolted.
»From below«:

The -subframe- is removed together with -pendulum support- and

-both suspension links-.
Both drive shafts are disconnected from gearbox and left installed
in wheel bearing housings. They are only swivelled to one side
and left on vehicle.

equipment required
♦ Support - 10-222A-
♦ Shackle - 10 - 222 A /12-
♦ Support - 10 - 222 A /31-
♦ Engine support basic set - T40091-
♦ Engine support supplement set - T40093-
♦ Gearbox support - 3282-

♦ Engine and gearbox

jack - V.A.G 1383 A-
or engine and gear‐
box jack - VAS 6931-
♦ Adjustment plate -
3282/42 A-
♦ Hose clamps to 25
mm - 3094-
♦ Tensioning strap -
T10038-
♦ Engine bung set -
VAS 6122-
♦ Insert tool, 18 mm -
T10179-
♦ Insert tool, 18 mm -
T10509-
♦ Socket, multi-point bit

- T10061-

♦ Counter-hold tool -
T10172A-
♦ Support bridge -
T10323-
♦ Adapter -
T40093/3-6- , qty. 2
(check and modify as
necessary
⇒ page 93 )
♦ or adapter -
T40093/3-6A- : qty. 2
Check adapters -
T40093/3-6- and modify
as necessary
– If necessary, cut off
the marked area.
– Round off front
edges.
– Protect adapter
against corrosion.
– Then, mark adapters
- T40093/3-6- as -
T40093/3-6A- .
At a later point, support
bracket - 10-222 A- will
be fitted onto longitudinal
members with adapters -
T40093/3-6A- .

• To prevent damage
to the longitudinal
members, wrap the
front section of the
adapters -
T40093/3-6A- with
textile-reinforced ad‐
hesive tape ⇒ Elec‐
tronic parts catalogue
(ETKA chemical sub‐
stances) .
Removing:
– Raise vehicle. All 4
supports of lifting
platform must be at
same height.
Note
So that the propshaft can

be turned later in order to
loosen it:
– Move selector lever

to »N« position.
– Remove complete air
filter housing ⇒ Rep.
gr. 23 ; Air filter; Re‐
moving and installing
air filter housing .
Battery in engine com‐
partment
– Remove battery and
battery tray ⇒ Electri‐
cal system; Rep. gr.
27 ; Battery; Remov‐
ing and installing bat‐
tery tray .
Battery in luggage com‐
partment
– Remove air filter housing bracket ⇒ Rep. gr. 23 ; Air filter;

Removing and installing air filter housing .
The bracket is similar to the one shown.
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
Removing and installing starter .

– Pry selector lever cable off selector shaft lever -arrow- using
an open-ended spanner.
Caution


– Clamp off coolant hoses using hose clamps to 40 mm - 3093-

or hose clamps to 25 mm - 3094- and remove.
– Seal connecting necks of gear oil cooler using suitable plugs
from engine bung set - VAS 6122- .
– Disconnect connector -1- for mechatronic unit for dual clutch

gearbox - J743- . To do this, turn rotary locking mechanism
anti-clockwise -arrow-.
– Remove air intake pipe ⇒ Rep. gr. 21 ; Charge air system;
Removing and installing air intake pipe .
– Unscrew upper engine/gearbox connecting bolts using insert

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

A bolt is located in the starter motor hole -arrow-. This bolt can be
removed using socket - T10061- .
– If there are hose and cable connections in area of engine sup‐
port eyes for support bracket - 10-222A- , remove these now.
– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system; Removing and installing wiper arms .
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Plenum chamber cover; Removing and
installing plenum chamber cover .
– Install support bracket - 10-222 A- as follows:

Required material:
♦ Adapter - 10 - 222 A /31-1-
♦ Adapter - 10 - 222 A /31-2-
♦ Connector - T40091/3-
♦ Square tube - T40091/1-
♦ Spindle from engine support supplement set - T40093 /3-
♦ Adapter - T40093/3-6- , qty. 2 (check and modify as necessary
⇒ page 93 )
♦ or adapter - T40093/3-6A- : qty. 2
– Detach cover caps on bolted connections for suspension
struts (front).
– Fit adapter - 10 - 222 A /31-1- and adapter - 10 - 222 A /31-2-
-A- onto suspension strut mountings.
The webs -arrow- must face towards front end.
– Slide connecting piece - T40091/3- onto support bracket -

10-222 A- .
– Bolt support bracket - 10-222 A- to adapter - 10 - 222 A /31-1-
and to adapter - 10 - 222 A /31-2- .
-A- = adapter - T40093/3-6A- (⇒ next figure)

– Remove fuel filter and lay to side. Do not open pipe/hose sys‐
tem ⇒ Rep. gr. 20 ; Fuel filter; Assembly overview - fuel filter .
– Place adapters - T40093/3-6A- onto both longitudinal mem‐
bers (illustration shows right longitudinal member).
– If necessary, carefully unclip any pipes for air conditioning
system in front area. Do not disconnect pipe/hose system ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - refrigerant circuit .
– Position adapter - T40093/3-6A- on left longitudinal member

directly behind filler pipe for washer fluid reservoir.
• Each of the adapters - T40093/3-6A- locks with pin -A- behind
the web of the longitudinal member -arrow-.
– Screw on spindle from engine support supplement set -
T40093 /3- , connect it via square tube - T40091/1- to engine
support bracket - 10-222 A- and fasten connection (⇒ previous
fig.).
• The square tube - T40091/1- must be flush with the connecting
piece - T40091/3- and the engine support supplement set -
T40093 /3- (⇒ previous figure).
– Then attach spindles to engine support eyes.
– Take up weight of engine/gearbox assembly and support
bracket on spindles .
sulation .
– Remove lower part of front left wheel housing liner ⇒ General
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; As‐
sembly overview - front wheel housing liner .
– Remove electrical wiring and retainers from sump at front

-arrows-.


sender - G266- .
Remove subframe. ⇒ Rep. gr. 40 ; Subframe; Assembly over‐
view - subframe
shaft .
– Disconnect both drive shafts from gearbox ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Drive shaft: Removing and in‐
stalling drive shafts .
Secure both drive shafts to suspension struts using tensioning

straps - T10038- .
The surface protection of the shafts must not be damaged.
– Unscrew bolts -A and B-, and remove gearbox carrier for bevel
box.


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


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

hole for subframe.
– A securing bolt from the subframe is suitable for this.
– Place cloth -A- on support and put propshaft on that.

Note
♦ When removing and installing, do not damage seal in the

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

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

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

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

engine/gearbox »only« on gearbox side as far as dimension
-a-.
Dimension -a- = about 110mm
The gearbox is separated from the engine in this position.
– Position engine and gearbox jack - V.A.G 1383 A- with gear‐
box support - 3282- under gearbox.

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

– Remove »last« connecting bolt between engine and gearbox.
– Push gearbox off engine and lower it carefully, ensuring
»clearance« to other components.
Transporting gearbox ⇒ page 153 .
Secure gearbox to assembly stand ⇒ page 159 .
Install gearbox ⇒ page 148 .
4.2.2 Removing gearbox, Passat 2015 ►,

Passat estate 2015 ►, Passat estate
2019 ► vehicles with petrol engine
Brief description
The gearbox is removed downwards separately.
»From above«:
The battery is disconnected and, if located in engine compart‐
ment, removed. The air filter and starter are removed. The engine
and gearbox must be supported before the left subframe mount‐
ing is removed.
»From below«:
-Subframe- is removed together with -pendulum support- and


equipment required
♦ Support - 10 - 222 A-
♦ Adapter - 10 - 222 A /29-
♦ Adapter - 10 - 222 A /18-
♦ Shackle - 10 - 222 A /12- qty. 2
♦ Pin - 3282/29-
♦ Engine and gearbox jack - V.A.G 1383 A- or engine and gear‐

box jack - VAS 6931-
♦ Adjustment plate - 3282/67-
♦ Hose clamps to 25 mm - 3094-
♦ Tensioning strap - T10038-
♦ Engine bung set - VAS 6122-

♦ Insert tool, 18 mm - T10179-

♦ Socket, multi-point bit

- T10061-
♦ Square tube -
T40091/1- , qty. 2
♦ Connecting piece -
T40091/3- , qty. 2
♦ Spindle - T40093 /3-
from engine support
supplementary set -
T40093- , qty. 2
♦ Adapter -
T40093/3-6- , qty. 2
(check and modify as
necessary
⇒ page 105 )
♦ or adapter -
T40093/3-6A- : qty. 2

Check adapters -
T40093/3-6- and modify
as necessary
– If necessary, cut off
the marked area.
– Round off front
edges.
– Protect adapter
against corrosion.
– Then, mark adapters
- T40093/3-6- as -
T40093/3-6A- .
At a later point, support
bracket - 10-222 A- will
be fitted onto longitudinal
members with adapters -
T40093/3-6A- .
• To prevent damage
to the longitudinal
members, wrap the
front section of the
adapters -
T40093/3-6A- with
textile-reinforced ad‐
hesive tape ⇒ Elec‐
tronic parts catalogue
(ETKA chemical sub‐
stances) .
Removing
– Raise vehicle. All 4
supports of lifting
platform must be at
same height.
– Move selector lever
to position »P«.
– Remove engine cov‐
er panel ⇒ Rep. gr.
10 ; Engine cover
panel; Removing and
installing engine cov‐
er panel .
Battery in engine com‐
partment
– Remove battery and
battery tray ⇒ Electri‐
cal system; Rep. gr.
27 ; Battery; Remov‐
ing and installing bat‐
tery tray .
Battery in luggage com‐
partment
– Disconnect battery ⇒
Electrical system;
Rep. gr. 27 ; Battery;
Disconnecting and
reconnecting battery .

– Remove air filter housing and bracket located beneath ⇒ Rep.

gr. 24 ; Air filter; Assembly overview - air filter housing .
Caution


– Remove air pipe ⇒ Rep. gr. 21 ; Charge air system; Assembly
– Lay lint-free cloths on gear oil cooler and gearbox to catch
escaping coolant.
Note
♦ On a warm engine, the cooling system is under high pressure.

♦ Before pulling off the coolant hoses, cover the cap on the
coolant expansion tank with a cloth and open carefully.
– Clamp off coolant hoses using hose clamps, up to 25 mm in

diameter - 3094- , and detach them.


– Remove starter -A- ⇒ Electrical system; Rep. gr. 27 ; Starter;
It is advisable to remove the lower bolt first.
– Unscrew all upper bolts securing engine to gearbox.
– Install support bracket - 10-222 A- as follows:
Required material:
♦ Adapter - 10 - 222 A /18-
♦ Shackle - 10 - 222 A /12- : qty 2 (required if spindles of support
bracket cannot be hooked into lifting eyes of engine).
♦ Adapter - 10 - 222 A /29- , qty. 2
♦ Square tube - T40091/1- , qty. 2
♦ Connecting piece - T40091/3- , qty. 2
♦ Spindles - T40093 /3- , qty. 2
♦ Adapter - T40093/3-6- , qty. 2 (check and modify as necessary
⇒ page 105 )
♦ or adapter - T40093/3-6A- : qty. 2
– On both sides of vehicle, insert adapters - 10 - 222 A /29- be‐

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

vehicle.
Arrow -2- always points in direction of travel.

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

T40091/3- onto support bracket - 10-222 A- .
– Secure support bracket - 10-222 A- to adapters - 10 - 222 A /
29- .
-A- = adapter - T40093/3-6A- (⇒ next figure)
– If present, pull off wires in front area of flange on both longi‐

tudinal members -arrow-. Do not disconnect pipe/hose sys‐
tem.
– Place adapters - T40093/3-6A- onto both longitudinal mem‐
bers (illustration shows right longitudinal member).
– If necessary, carefully unclip any pipes for air conditioning
system in front area. Do not disconnect pipe/hose system ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - refrigerant circuit .
– Position adapter - T40093/3-6A- on left longitudinal member

directly behind filler pipe for washer fluid reservoir.
• Each of the adapters - T40093/3-6A- locks with pin -A- behind
the web of the longitudinal member -arrow-.
– Screw in spindles - T40093 /3- .
– Connect spindles - T40093 /3- via square tubes - T40091/1-
to engine support bracket - 10-222 A- , and tighten (⇒ previous
illustration).
Rep. gr. 66 ; Noise insulation .


-arrows-.

sender - G266- .
– Remove subframe ⇒ Rep. gr. 40 ; Subframe; Assembly over‐
view - subframe .
– Unbolt drive shafts from gearbox ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Drive shaft .
– Secure drive shaft to suspension strut with tensioning strap -

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

– Unscrew bolts -A- and -B- from bevel box and remove heat
shield -1-.





hole for subframe.
Note



gearbox.


-a-.

Note
Be careful of all lines when lowering gearbox.

4.2.3 Removing gearbox, Tiguan 2016 ► ve‐

hicles with 2.0 l - 105 kW, 110 kW, 130
kW, 140 kW diesel engine, all-wheel
drive
Brief description
»From above«:
The battery, air filter and starter are removed. Wiring harness of
steering rack is disconnected and »moved clear«. This allows it
to be lowered together with subframe and steering rack. The en‐
gine and gearbox must be supported before the left and right
assembly mounting is removed.
»From below«:
Remove noise insulation beneath engine and cover in front left
wheel housing.


-steering rack-.
Both drive shafts are pushed out of gearbox and left installed in
wheel bearing housings. They are only swivelled to one side, but
are left on vehicle.

equipment required
♦ Support - 10 - 222 A-
♦ Adapter - 10 - 222 A /29-
♦ Adapter - 10 - 222 A /18-
♦ Shackle - 10 - 222 A /12-
♦ Pin - 3282/29-
♦ Engine and gearbox jack - VAS 6931-


♦ Insert tool 18 mm - T10179- or insert tool AF 18 - T10509-
♦ Bar - 2024 A / 1- of lifting tackle - 2024 A-

♦ Socket, multi-point bit - T10061-
♦ Adapter - 10 - 222 A /3-
♦ Support bridge - T10323-
♦ Adapter - 10 - 222 A /16-
Removing
height.
– Remove engine cover panel ⇒ Rep. gr. 10 ; Engine cover
panel; Removing and installing engine cover panel .
– Remove battery with battery tray ⇒ Electrical system; Rep.
gr. 27 ; Battery; Removing and installing battery tray .

Caution






port eyes for support bracket - 10 - 222 A- , remove these now.
– Remove gas strut of bonnet from bottom ball-head pin and
prop up bonnet using workshop means ⇒ General body re‐
pairs, exterior; Rep. gr. 55 ; Bonnet; Removing and installing
gas strut .
– Mount support bracket - 10-222 A- :
Required material:
♦ Adapter - 10 - 222 A /3-
♦ Adapter - 10 - 222 A /18-
♦ Shackle - 10 - 222 A /12-
♦ Adapter - 10 - 222 A /29- , qty. 2
♦ Adapter - 10-222A/16-
♦ Fish plate - 2024 A / 1-
♦ Bracket - T10346-
♦ Bracket - T10346/1-
♦ Flange bolt M6 x 40

wing underneath it.
“L” = -1-, adapter is inserted on “right” side of vehicle
“R” (not shown in illustration), adapter is to be inserted on “left”
side of vehicle
Position adapters - 10-222A/29- behind console -1- next to shoul‐

der -2- in each case.

• First, slide adapter - 10-222A/16- onto left side of support

bracket ⇒ page 117 .
• Adapter - 10-222A/16- serves to secure support bracket dur‐
ing subsequent work routine.
• Once support bracket is complete, adapter - 10-222A/16- is
located between adapter - 10 - 222 A /18- and left adapter -
10 - 222 A /29- .
– Push adapter - 10 - 222 A /18- and adapter - 10 - 222 A /3-
onto support bracket - 10-222 A- .
Secure support bracket - 10-222 A- as shown

– Bolt bracket - T10346- or -T10346/1- to rear left mounting hole
for battery tray.
– To do this, use a flange bolt M6 × 40 or a securing bolt for
battery tray.
Note
Attach shackle - 10 - 222 A /12- to uppermost hole of fish plate -

2024 A / 1- .
– Secure bar - 2024 A / 1- with locating pin -arrow-.

Rep. gr. 66 ; Noise insulation; Removing and installing noise
insulation .

-arrows-.


sender - G266- .
view - subframe
shaft .

straps - T10038- .
box.





hole for subframe.

Note




gearbox.

-a-.


4.2.4 Removing gearbox, Tiguan 2016 ►, ve‐

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


equipment required
♦ Support - 10 - 222 A-
♦ Hook - 10-222A/10-
♦ Adapter - 10-222A/28-
♦ Adapter - 10-222A/28-2-
♦ Adapter - 10 - 222 A /29- , qty. 2
♦ 2 × -T40091/1- and -T40091/3- from engine support basic set
- T40091-
♦ 2 × swivel joints - T40093/3- from engine support supplemen‐
tary set - T40093-


♦ Shackle - 10 - 222 A /12-
♦ Pin - 3282/29-

Removing
height.
– Move selector lever to position »P«.
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery tray .
Caution


– Remove charge air pipe with charge air hose ⇒ Rep. gr. 21 ;
Charge air system; Assembly overview - charge air system .
escaping coolant.
Note
♦ On a warm engine, the cooling system is under high pressure.

♦ Before pulling off the coolant hoses, cover the cap on the
coolant expansion tank with a cloth and open carefully.
– Clamp off coolant hoses using hose clamps, up to 25 mm in

diameter - 3094- , and detach them.


– Remove starter -A- ⇒ Electrical system; Rep. gr. 27 ; Starter;
It is advisable to remove the lower bolt first.
– Unscrew all upper bolts securing engine to gearbox.
Supporting engine
– Remove foam elements -arrows- on left and right for plenum

chamber seal.


tween wing and mounting plate for wing located underneath.

side of vehicle
– Push 2 swivel joints - T40091/3- onto support bracket - 10-222
A- .
– Secure support bracket - 10-222 A- to adapters - 10 - 222 A /
29- .
– Unscrew bolts -arrows- for lock carrier bracket on left and right.
– Unscrew lower supports from adapters - 10 - 222 A /28- and

replace them with adapters -10-222 A /28-2- .
– Unscrew bolts -arrows- for attaching engine support to lock
carrier from adapter - 10-222 A /28-2- .
– Bolt adapter - 10-222 A /28-2- to lock carrier using securing

bolt -1-. Specified torque: 8 Nm.

– Set-up square tubes - T40091/1- with one spindle each as

shown.
– Engage spindles in support eyes of engine. Use shackle - 10
- 222 A /12- if necessary.
– Take up weight of engine/gearbox assembly using spindles .
Rep. gr. 66 ; Noise insulation .

-arrows-.

sender - G266- .
– Remove subframe ⇒ Rep. gr. 40 ; Subframe; Assembly over‐
view - subframe .
– Unbolt drive shafts from gearbox ⇒ Running gear, axles,
– Secure drive shaft to suspension strut with tensioning strap -

T10038- .

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





hole for subframe.
Note




gearbox.

-a-.

Note
Be careful of all lines when lowering gearbox.



hicles with diesel engine, front-wheel
drive
Brief description
The gearbox is removed downwards separately. The engine re‐
mains in the vehicle.
Battery, battery carrier and air cleaner housing are removed
»from above«. Engine and gearbox must then be supported so
that left and right assembly mounting can be detached.
»From below«:
wheel housing.
-steering rack-.

equipment required
♦ Support - 10 - 222 A-

♦ Adapter - 10 - 222 A /29-

♦ Adapter - 10 - 222 A /18-
♦ Shackle - 10 - 222 A /12-
♦ Pin - 3282/29-


♦ Adapter - 10 - 222 A /3-
♦ Adapter - 10 - 222 A /16-
Removing
height.


Caution






gas strut .
Required material:
♦ Adapter - 10 - 222 A /3-
♦ Adapter - 10 - 222 A /18-
♦ Shackle - 10 - 222 A /12-
♦ Adapter - 10 - 222 A /29- , qty. 2
♦ Adapter - 10-222A/16-
♦ Fish plate - 2024 A / 1-
♦ Bracket - T10346/1-

wing underneath it.
side of vehicle



10 - 222 A /29- .

for battery tray.
battery tray.
Note

2024 A / 1- .

Rep. gr. 66 ; Noise insulation; Removing and installing noise
insulation .


-arrows-.

sender - G266- .
– Remove subframe. ⇒ Running gear, axles, steering; Rep. gr.
40 ; Subframe; Assembly overview - subframe

straps - T10038- .



gearbox.

-a-.
Note
The following diagrams show the gearbox in the all-wheel drive

version. The procedure for supporting the weight of the gearbox
is the same as that for front-wheel drive.



hicles with 2.0 l - 176 kW TDI
Brief description
»From above«:
The battery, air filter and starter are removed. Wiring harness of
steering rack is disconnected and »moved clear«. This allows it
to be lowered together with subframe and steering rack. The en‐
gine and gearbox must be supported before the left and right
assembly mounting is removed.
»From below«:
wheel housing.
-steering rack-.

equipment required
♦ Support - 10 - 222 A-

♦ Adapter - 10 - 222 A /29-

♦ Adapter - 10 - 222 A /18-
♦ Shackle - 10 - 222 A /12-
♦ Pin - 3282/29-


♦ Adapter - 10 - 222 A /3-
♦ Support bridge - T10323-

♦ Adapter - 10 - 222 A /16-
Removing
height.

Caution






gas strut .
Required material:
♦ Adapter - 10 - 222 A /3-
♦ Adapter - 10 - 222 A /18-
♦ Shackle - 10 - 222 A /12-
♦ Adapter - 10 - 222 A /29- , qty. 2
♦ Adapter - 10-222A/16-
♦ Fish plate - 2024 A / 1-
♦ Bracket - T10346/1-

wing underneath it.
side of vehicle



10 - 222 A /29- .

for battery tray.
battery tray.
Note

2024 A / 1- .

sulation .

-arrows-.


sender - G266- .
view - subframe
shaft .

straps - T10038- .
box.





hole for subframe.

Note




gearbox.

-a-.


4.3 Installing gearbox

Install in the reverse order of removal observing the following:

– Renew needle bearing in crankshaft ⇒ Rep. gr. 13 ; Crank‐

shaft; Renewing needle bearing in crankshaft .
Note
If the needle bearing in the crankshaft is damaged, the gears

cannot be selected properly any more because the clutch is sup‐
ported on this bearing.
– Lightly grease journal and splines on gearbox.

– Check for proper seating of both dowel sleeves between en‐
gine and gearbox.
– Check for proper seating of intermediate plate.
It must be possible to guide the engine and gearbox together by
hand until the engine flange and gearbox flange make contact all
around.
– If necessary, readjust gearbox support until engine and gear‐
box are »aligned with each other«.
– Turn crankshaft slightly if necessary.
Install gearbox, taking care not to pinch any lines.
– Tighten gearbox to engine.
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Re‐
moving and installing starter .
– If engine and gearbox were removed, install them ⇒ Rep. gr.
10 ; Removing and installing engine; Installing engine
Pay attention to selector lever cable when installing. Guide cable
as soon as possible into cable support bracket.
– Install subframe. ⇒ Running gear, axles, steering; Rep. gr.
40 ; Subframe; Assembly overview - subframe
– Install drive shaft ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shaft; Removing and installing drive shafts .
– Check coolant level ⇒ Rep. gr. 19 ; Cooling system, coolant;
Draining and filling coolant .
gr. 66 ; Noise insulation; Removing and installing noise insu‐
lation .

5 Assembly mountings
⇒ “5.1 Assembly overview - assembly mountings”, page 150
5.1 Assembly overview - assembly mountings
1 - Bolt
❑ Specified torque ⇒ Rep.
gr. 10 ; Assembly
mountings; Assembly
overview - assembly
mountings
2 - Engine support
❑ ⇒ Rep. gr. 10 ; Assem‐
bly mountings; Assem‐
bly overview - assembly
mountings
3 - Engine mounting
❑ ⇒ Rep. gr. 10 ; Assem‐
bly mountings; Assem‐
bly overview - assembly
mountings
4 - Bolt
gr. 10 ; Assembly
mountings; Assembly
overview - assembly
mountings
5 - Bolt
gr. 10 ; Assembly
mountings; Assembly
overview - assembly
mountings
6 - Bolt
gr. 10 ; Assembly
mountings; Assembly
overview - assembly
mountings
7 - Bolt
❑ Specified torque ⇒ Rep. gr. 10 ; Assembly mountings; Assembly overview - assembly mountings
8 - Pendulum support
9 - Bolt
❑ For pendulum support to subframe
10 - Bolt
❑ For pendulum support to gearbox
❑ Gearbox with threaded insert ⇒ page 151
11 - Bolt
❑ For pendulum support to gearbox
❑ Gearbox with threaded insert ⇒ page 151

12 - Bolt
❑ For securing gearbox mounting to gearbox console.
❑ Tightening sequence ⇒ page 152
❑ 60 Nm +90°
13 - Bolt
❑ For securing gearbox mounting to gearbox console.
❑ Qty. 2
❑ 60 Nm +90°
14 - Gearbox mounting
❑ Check adjustment ⇒ Rep. gr. 10 ; Assembly mountings; Assembly overview - checking adjustment of
assembly mountings
❑ Adjust ⇒ Rep. gr. 10 ; Assembly mountings; Adjusting assembly mountings
15 - Bolt
❑ Gearbox mounting to body
16 - Bolt
❑ For securing gearbox console to gearbox.
❑ 40 Nm +90°
17 - Gearbox bracket
❑ Illustration does not correspond to version in vehicle.
18 - Bolt
❑ For securing gearbox console to gearbox.
❑ 40 Nm +90°
Gearbox with threaded insert (e.g. “Heli-Coil”) for securing pen‐

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

for the pendulum support.
♦ Distinguishing feature: shoulder along beginning of thread
-arrow-.
♦ Note appropriate securing bolts and specified torque ⇒ Rep.
gr. 10 ; Assembly mountings; Assembly overview - assembly
mountings .
5. Assembly mountings 151

Install left assembly mounting as follows:

– Renew all bolts -1- and -2-.
– First screw in all new bolts by hand.
– Then tighten bolts -1- of gearbox bracket -A-.
– The gearbox bracket -A- can be levered into its seat with a
screwdriver while bolts -2- are being tightened.

6 Transporting gearbox
♦ Lifting tackle - 2024 A-
♦ Workshop hoist - VAS 6100-
Always secure heavy parts when transporting them.

Also remember there is oil in the gearbox. Do not turn gearbox
with breathers downwards during transport or while on repair
stand. Oil will run out.
Note
If necessary, pull off breather cap and close using suitable plugs
to achieve an oil-tight seal.
Transporting gearbox
Gearbox can be lifted with lifting tackle - 2024 A- .
6. Transporting gearbox 153

7 Dismantling and assembling gearbox
7.1 Assembly overview - gearbox

⇒ “7.1.1 Renewing bleeder”, page 156
⇒ “7.1.2 Renewing sealing cap”, page 156
1 - Retaining ring
❑ Renew
2 - Clutch end cover
❑ A cover which has been
removed must not be in‐
stalled again.
❑ Lubricate external seal
with dual clutch gearbox
oil - G 052 182 A2- be‐
fore installing.
⇒ page 12
3 - Retaining ring
❑ Renew
4 - Shim
❑ Determine thickness
again if a new clutch has
been fitted ⇒ page 11
5 - Tapered ring
6 - Clutch
⇒ page 11
7 - Sealing ring, right
⇒ page 186
8 - Breather pipe
⇒ page 156
9 - Breather cap
10 - Plug
11 - Seal
❑ Renew
12 - Gear oil cooler
❑ Removing and installing gear oil cooler ⇒ page 160
13 - Bolt, 20 Nm + 45°
❑ Renew
14 - Filter housing, 20 Nm
15 - Seal
❑ Renew

16 - Heat shield
17 - Oil filter
18 - Bolt, 5 Nm + 90°
❑ Renew
19 - Cable support bracket
❑ For selector lever cable to gearbox
20 - Gearbox selector lever
21 - Bolt, 10 Nm + 90°
❑ Renew
22 - Gearbox
23 - Left seal
24 - Seal
❑ Renew
25 - Oil drain plug, 20 Nm
❑ For mechatronic unit
26 - Oil level pipe, 3 Nm
Caution
Comply
♦ with the torque
setting precisely.
The
♦ oil level pipe can
break between the
thread and the collar.
Note
♦ The oil level pipe comes in dif‐

ferent lengths and colours.
♦ If the oil level pipe is renewed, it
is essential that the oil level pipe
appropriate for the gearbox is in‐
stalled ⇒ Electronic Parts Cata‐
logue “ETKA” .
♦ Do not install the oil level pipe
from another gearbox! The oil
level pipe determines the oil level
in the gearbox.
♦ Fitting a different oil level pipe
can result in the oil level in the
gearbox being too high or too
low.
❑ Drain and fill oil ⇒ page 166
27 - Seal
❑ Renew
28 - Oil drain plug, 45 Nm
29 - Bolt, 10 Nm
30 - Gearbox input speed sender - G182- and oil temperature sender in multi-plate clutch - G509-
7. Dismantling and assembling gearbox 155

31 - Mechatronic unit for dual clutch gearbox - J743-

32 - Bolt, 8 Nm + 45°
❑ Renew
33 - Cover
❑ With seal
❑ Renew
34 - Bolt, 10 Nm + 45°
❑ Renew
35 - Securing clip
❑ Renew
36 - Seal
❑ Renew
7.1.1 Renewing bleeder

Removing
– Pull off cap -arrow- by hand.
– Insert screwdriver -1- between collar of gearbox and breather

pipe -2-.
– Pry off breather pipe -2- with screwdriver -1-.
Installing
– Push on breather pipe -2- powerfully by hand.
Breather pipe must be heard and felt to engage.
– Put on cap.
7.1.2 Renewing sealing cap


♦ -1- Internal puller - Kukko 21/2-
♦ -4- Counter support - Kukko 22/1-

♦ Special wrench - T40297-
♦ Knife, commercially available

Removing
height.
– Remove front left wheel.
– Remove front left wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liners; Removing and
installing front wheel housing liner .
– Pierce centre of cap with a knife -1- and remove rubber coating
around it. Diameter of opening approx. 15 mm.
7. Dismantling and assembling gearbox 157

– Pull sealing cap out of gearbox housing using internal puller

14 … 19 mm -B-, e.g. -Kukko 21/2- , and counter support
-A-, e.g. -Kukko 22/1- .
– Thoroughly clean sealing surface on gearbox housing with a
lint-free cloth.
Installing
– Using key - T40297- , drive new sealing cap into gearbox

housing to stop. Take care not to cant sealing cap.
– Check gear oil level ⇒ page 164 .
– Install front left wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liner; Removing and
installing front wheel housing liner .
– Install front left wheel ⇒ Running gear, axles, steering; Rep.
gr. 44 ; Wheels, tyres; Changing wheels .

8 Securing to engine and gearbox sup‐

port
Keep in mind that there is oil in the gearbox. Do not turn gearbox
with breathers downwards during transport or while on repair
stand. Oil will run out.
Note
If necessary, pull off breather cap and close using suitable plugs
to achieve an oil-tight seal.
Example: securing gearbox to assembly stand.
8. Securing to engine and gearbox support 159

9 Gear oil circuit
9.1 Removing and installing gear oil cooler


Removing
– Move selector lever to position “P”.
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery .
escaping coolant.
– Clamp off coolant hoses using hose clamps -3094- and re‐
move from cooler.
– Unscrew bolts -arrows- and remove gear oil cooler -A-.
Caution
No coolant must be allowed to drip into gearbox!

Installing
♦ Renew O-rings -arrows- after each removal.
♦ Coat O-rings with gear oil to prevent pinching of rings during
assembly.
♦ If sealing surface on gear oil cooler is damaged, it must be
renewed.
– Carefully remove strainer -1- of oil cooler, if present, with a

screwdriver and check for contamination.
– Clean strainer if necessary and clip back in place.
– Carefully bring gear oil cooler -A- into position. When doing
this, observe sealing surface and O-rings.
– Screw in new bolts -arrows- incrementally in diagonal se‐
quence and tighten to 20 Nm + 45°.
– Attach coolant hoses to gear oil cooler and remove hose

clamps -3094- .
– Install battery with battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery .
– Install air filter housing ⇒ Rep. gr. 23 ; Air filter; Removing
and installing air filter housing .
– Check coolant level and top up with coolant as needed ⇒ Rep.
gr. 19 ; Cooling system, coolant; Draining and filling coolant .
– Checking and adjusting oil level ⇒ page 164 .
9.2 Removing and installing gear oil filter

Oil filter change – »yes or no?«
The oil filter does not have to be changed as a matter of course.
Do not change the filter if:
♦ The gear oil cooler or its O-rings have been renewed and no
coolant has got into the oil.
9. Gear oil circuit 161

♦ The oil seal for the selector shaft has been renewed.
♦ The oil seal for the flange shaft was renewed.
♦ Leaking covers in the mechatronic unit, dual clutch or oil pump
have been renewed.
The filter must be changed if:
♦ Coolant has got into the oil.
♦ Metal particles have been found in the oil.
♦ The clutch is burnt out or has a mechanical defect.
Note
Refer to general repair instructions ⇒ page 6 .
Removing
– Remove air pipe ⇒ Rep. gr. 21 ; Charge air system; Assembly
Note
♦ A residual amount of oil remains in oil filter. It runs out when

filter housing is unscrewed.
♦ Before unscrewing the filter housing, cover the area around
the oil filter with a sufficient number of cloths.
– First loosen filter housing -1- by about 7 turns.

– Wait about 10 seconds.
This allows the oil to flow from filter housing back into gearbox.
– Now remove filter housing with filter.
– Renew missing or damaged heat shield -2-.
Installing
the following:
– Thoroughly clean oily areas on gearbox.

– Insert new oil filter with collar -arrow- downwards.

– Screw in filter housing and tighten to 20 Nm.
– Install air pipe ⇒ Rep. gr. 21 ; Charge air system; Assembly
– Check oil level and top up ⇒ page 164 .
9. Gear oil circuit 163

10 Gear oil
10.1 Checking gear oil level

If DSG oil must be added, use only oil listed in ⇒ Electronic parts
catalogue “ETKA” .
♦ Vehicle diagnosis, testing and information system - VAS
5051B-
♦ Used oil collection and extraction unit - V.A.G 1782-
♦ Adapter for oil filling - VAS 6262 A-
Prerequisites
♦ Vehicle level, all mountings of lifting platform evenly at same
height
♦ Noise insulation removed
5051B- is connected.
♦ At start of work, oil temperature must not be above 45°C.
♦ Test temperature: 35 - 45°C

Check
– Connect vehicle diagnosis, testing and information system -
VAS 5051B- and identify the vehicle in Guided functions .
– Select Dual clutch gearbox .
– Select Check oil level .
Note
If the oil temperature is above 45°C, allow the gearbox to cool

down.
Engine is running at idling speed with selector lever in “P”.

– Remove oil drain plug -arrow-.
– Renew oil seal -arrow- of bolt.
Note
Even if oil level is too low, a small amount of oil will initially run out
of oil level pipe because pipe fills up during operation.
– Let surplus oil flow out.

– When excess oil has run out (when it begins only to drip), in‐
stall plug with new seal.
– Top up oil if no oil flows out.
Topping up
10. Gear oil 165

– Before screwing adapter for oil filling - VAS 6262 A- onto oil
bottle, measure length of breather pipe, dimension -a-, and
shorten it as necessary.
Dimension -a- = 210 mm
Note
The dimension -a- is measured from the shaft (green area in the
magnifying glass) of the adapter for oil filling - VAS 6262 A- .
– Screw adapter of adapter for filling oil - VAS 6262 A- hand-

tight into inspection hole.
WARNING
Shake bottles thoroughly before opening to ensure that sedi‐

ment at the bottom of the bottle mixes well with the oil.
– Fill 1.0 litres of oil.

– Pull off adapter for oil filling - VAS 6262- at plug-in connector
and check:
If oil now flows out of hole in adapter:
Oil does not need topping up.
– Allow surplus oil to drain out.
– When excess oil has run out (when it begins only to drip), re‐
move adapter for filling oil - VAS 6262 A- and install plug with
new seal.
If no oil drips out of inspection hole:
– If a further litre has to be added ⇒ page 164 .
WARNING
An oil level which is too low or too high will impair the function
of the gearbox.
Torque setting for drain plug: 45 Nm
10.2 Draining and filling gear oil

If DSG oil must be added, use only oil listed in ⇒ Electronic parts
catalogue “ETKA” .
Please also refer to the notes on the oil filter change regarding
»dirty oil« ⇒ page 161 .
Brief description
First read the oil temperature. If it is above 50°C, allow the gear‐
box to cool down.
With engine stopped, unscrew and remove overflow pipe and let
the oil drain out. Then reinstall overflow pipe and »overfill« gear‐
box with oil.
Then start engine and drain excess oil until oil level attains level
of overflow pipe.


5051B-
♦ Used oil collection and extraction unit - V.A.G 1782-
♦ Adapter for oil filling - VAS 6262 A-
Prerequisites
♦ Engine switched off
♦ Vehicle level, all mountings of lifting platform evenly at same
height
♦ Noise insulation removed if previously fitted
♦ Selector lever at “P”
5051B- is connected.
♦ At start of work, oil temperature must not be above 45 °C.
Procedure
– Comply with rules for cleanliness when working on gearbox
⇒ page 5 .
– Only gear oil available as spare part is allowed to be used for
dual clutch gearbox. Other oils will lead to malfunctions or fail‐
ure of the gearbox ⇒ Electronic Parts Catalogue (ETKA) .
10. Gear oil 167

WARNING
Danger of injury from hot gear oil!
– Connect vehicle diagnosis, testing and information system -

VAS 5051B- and identify the vehicle in Guided functions .
– Select Dual clutch gearbox .
– Select Check oil level .
Note
If the oil temperature is higher than 45°C, allow gearbox to cool

down.
WARNING
Do not start engine if there is no oil in gearbox.
– Engine switched off - do not start engine!

– Remove oil drain plug -arrow-.
– Renew oil seal -arrow- of bolt.

– Remove oil level pipe -arrow- and allow oil to run out.
– Remove oil drain plug -arrow- from mechatronic unit.
Note
A further approx. 1.2 litres of oil will run out.
– Renew seal -arrow- and reinstall oil drain plug of mechatronic

unit, tightening to 20 Nm.
Note
♦ Normally, there is no need to remove oil filter.

♦ Oil filter change “Yes or no?” ⇒ page 161
– Screw oil level pipe -arrow- in to stop and tighten to 3 Nm.
10. Gear oil 169

– Before screwing adapter for oil filling - VAS 6262 A- onto oil
bottle, measure length of breather pipe, dimension -a-, and
shorten it as necessary.
Dimension -a- = 210 mm
Note
The dimension -a- is measured from the shaft (green area in the
magnifying glass) of the adapter for oil filling - VAS 6262 A- .
– Screw adapter of adapter for filling oil - VAS 6262 A- hand-

tight into inspection hole.
WARNING
Shake bottles thoroughly before opening to ensure that sedi‐

ment at the bottom of the bottle mixes well with the oil.
During filling, the adapter for oil filling - VAS 6262 A- and bottle
must always be held higher than the gearbox.
– Fill 5.5 litres of oil.
– When changing bottles, close tap on adapter.
– Close tap on adapter when 5.5 litres of oil have been added
to gearbox.
– Start engine. The adapter for filling oil - VAS 6262 A- may re‐
main connected.
– Depress brake pedal and select each selector lever position
for about 3 seconds, then move lever back to »P«
– Do NOT switch off engine.
– Then check oil level and top up. ⇒ page 164

35 – Gears, shafts
1 Currently, no repairs can be made to
gears and shafts
1. Currently, no repairs can be made to gears and shafts 171

39 – Final drive - differential

1 Gear oil
⇒ “1.1 Checking gear oil level”, page 172
⇒ “1.2 Draining and filling gear oil”, page 174
1.1 Checking gear oil level

⇒ “1.1.1 Checking gear oil level, bevel box 0A6 ”, page 172
⇒ “1.1.2 Checking gear oil level, bevel box 0CP ”, page 173
1.1.1 Checking gear oil level, bevel box “0A6”

♦ Used oil collection and extraction unit - VAS 6622A-
Note
♦ The bevel box is bolted to side of the gearbox and has its own
oil supply.
♦ Specifications for gear oil ⇒ Electronic Parts Catalogue “ET‐
KA”
Requirement
• Bevel box must be in installation position.
height.
sulation .
– Put used oil collection and extraction unit - VAS 6622A- un‐
derneath.
172 Rep. gr.39 - Final drive - differential

– Unscrew oil filler plug -1-.

Renew oil filler plug after each removal.
Oil level is correct when bevel box is filled to lower edge of filler
hole.
Note
♦ Clean bevel box thoroughly to remove any remains of the

emerged oil.
♦ Disregard -item 2-.
– If necessary, top up gear oil ⇒ page 174 .

– Screw in new oil filler plug -1-.
– Tighten bolt to specified torque ⇒ page 189 .
1.1.2 Checking gear oil level, bevel box “0CP”

Note
♦ The bevel box is bolted to side of the gearbox and has its own
oil supply.
♦ Specifications for gear oil ⇒ Electronic Parts Catalogue “ET‐
KA”
Requirement
• Bevel box must be in installation position.
height.
sulation .
– Before starting work, check which bevel box is installed
⇒ page 34 .
– Put used oil collection and extraction unit - VAS 6622A- un‐
derneath.
1. Gear oil 173


Renew oil filler plug after each removal.
• On current bevel boxes, the oil level is beneath the oil filler
hole and can therefore not be checked.
• Should the oil level be up to the lower edge of the oil filler hole,
extract 100 ml of gear oil ⇒ page 177 .
Note
♦ Clean bevel box thoroughly to remove any remains of the

emerged oil.
♦ Disregard -item 2-.
– If necessary, top up gear oil ⇒ page 174 .

– Screw in new oil filler plug -1-.
– Tighten bolt to specified torque ⇒ page 191 .
1.2 Draining and filling gear oil

⇒ “1.2.1 Draining and filling gear oil, bevel box 0A6 ”, page 174
⇒ “1.2.2 Draining and filling gear oil, bevel box 0CP ”, page 177
1.2.1 Draining and filling gear oil, bevel box

“0A6”
Note
♦ The gear oil in the bevel box must only be drained in the event
of repairs. The oil is not intended to be changed on a regular
basis.
♦ Specifications for gear oil ⇒ Electronic Parts Catalogue


♦ Filling device - VAS 6291 A-
♦ Adapter for oil filling - VAS 6291/3-
♦ For some oil bottles adapter - VAS 6262/6- must be used as

well.

Requirement
• Vehicle is level.
height.
sulation .
– If fitted, remove right drive shaft heat shield from bevel box
-arrows- ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive
shaft; Removing and installing drive shaft .
– Place used oil collection and extraction unit - VAS 6622- below
gearbox.
1. Gear oil 175

WARNING
Risk of injury from hot gear oil.

♦ Wear protective goggles.
♦ Wear acid-resistant gloves
– Unscrew oil drain plug -2-, and drain gear oil.

– Screw in new oil drain plug.
Note
To collect escaping gear oil, leave used oil collection and extrac‐
tion unit - VAS 6622- underneath.

– Screw adapter for oil filling -VAS 6291/3- in to stop.

– Engage angled piece of filling device for all-wheel drive cou‐
pling 2 - VAS 6291 A- with adapter for oil filling -VAS 6291/3- .
• Do not allow hose to sag.
– Top up with oil.
Note
♦ If bevel box has been properly filled, oil runs out at adapter
-A-.
♦ Continue with filling procedure if no oil has run out yet.
– After bevel box has been properly filled, unscrew adapter -

VAS 6291/2- .
– Screw in »old« oil drain plug and tighten slightly.
– Start engine, engage gear and allow gearbox to turn for ap‐
prox. 2 minutes.
– Turn off engine and unscrew plug from oil filler hole.
– Check oil level, if necessary top up gear oil again to lower edge
of filler hole.
– Screw in new oil filler plug.
Note
Clean bevel box thoroughly to remove any remains of the

emerged oil.
– If present, install heat shield above right drive shaft ⇒ Running

gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and
installing drive shaft .
tion .
1.2.2 Draining and filling gear oil, bevel box

“0CP”
Note
♦ The gear oil in the bevel box must only be drained in the event
of repairs. The oil is not intended to be changed on a regular
basis.
♦ Specifications for gear oil ⇒ Electronic Parts Catalogue
1. Gear oil 177

♦ Filling device - VAS 6291 A-
♦ Adapter for oil filling - VAS 6291/3-
♦ For some oil bottles adapter - VAS 6262/6- must be used as

well.

Requirement
• Vehicle is level.
height.


sulation .
– If fitted, remove right drive shaft heat shield from bevel box
shaft; Removing and installing drive shaft .
– Place used oil collection and extraction unit - VAS 6622- below
gearbox.
WARNING
Risk of injury from hot gear oil.

♦ Wear protective goggles.
♦ Wear acid-resistant gloves
– Unscrew oil drain plug -2-, and drain gear oil.

– Screw in new oil drain plug.
Note
To collect escaping gear oil, leave used oil collection and extrac‐
tion unit - VAS 6622- underneath.
1. Gear oil 179

– Screw adapter for oil filling -VAS 6291/3- in to stop.

– Engage angled piece of filling device for all-wheel drive cou‐
pling 2 - VAS 6291 A- with adapter for oil filling -VAS 6291/3- .
• Do not allow hose to sag.
– Top up with oil.
Note
♦ If bevel box has been properly filled, oil will emerge from
adapter for oil filling -VAS 6291/3- .
♦ Continue with filling procedure if no oil has run out yet.
– If gear oil has emerged from adapter for oil filling - VAS
6291/3- , position oil container so that surplus oil can run back
into it.
– When no more oil flows back, remove filling device for all-
wheel drive coupling 2 - VAS 6291 A- .
– Remove adapter - VAS 6291/3- .
Caution
The correct oil level is beneath the oil filler hole and cannot be
checked.
If an elevated level is not rectified after filling, oil could escape
through the breather while the vehicle is being driven.
The correct oil level can only be achieved by extracting 100 ml
of gear oil after filling.
– Extract 100 ml of gear oil from the bevel box using a commer‐
cially available syringe with hose measuring max. ∅ 6 mm.
– Screw in new oil filler plug.
Note
Clean bevel box thoroughly to remove any remains of the

emerged oil.
– If present, install heat shield above right drive shaft ⇒ Running

gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and
installing drive shaft .
tion .

2 Oil seals
⇒ “2.1 Overview of fitting locations - seals”, page 181
⇒ “2.2 Renewing left seal”, page 181
⇒ “2.3 Renewing right oil seal”, page 184
⇒ “3.2 Renewing bevel box seals”, page 193
2.1 Overview of fitting locations - seals
1 - Stub shaft O-ring

❑ Renew
2 - Seal right, bevel box
⇒ page 196
3 - Stub shaft
4 - Right oil seal, stub shaft
❑ Item can be disregarded
5 - Output shaft seal
⇒ page 193
6 - Deflector ring
❑ Item can be disregarded
7 - Left oil seal, stub shaft
⇒ page 193
8 - Seal left, bevel box
⇒ page 193
9 - Sealing ring, right
❑ Removing and instal‐
ling, front-wheel drive
⇒ page 184
❑ Removing and instal‐
ling, four-wheel drive
⇒ page 186
10 - Left seal
⇒ page 181
2.2 Renewing left seal
2.2.1 Renewing oil seal for left flange shaft

2. Oil seals 181

♦ Puller - T10055-
♦ Thrust piece - T10457-
♦ Drip tray for workshop hoist - VAS 6208-
♦ Electric drill, commercially available

Removing
– Remove left drive shaft ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Drive shafts; Removing and installing drive shafts .
Note
Only drill through sheet metal ring (about 3 mm), otherwise bear‐
ing located behind it might be damaged.

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

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

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

cant oil seal in the process.
2. Oil seals 183

– Grease splines -arrow- of stub shaft with universal grease -

G 060 735 A2- .
– Install left drive shaft ⇒ Running gear, axles, steering; Rep.
2.3 Renewing right oil seal

⇒ “2.3.1 Renewing seal on right of gearbox, front-wheel drive ve‐
hicles”, page 184
⇒ “2.3.2 Renewing seal on right of gearbox, vehicles with all wheel
drive”, page 186
⇒ “3.2.2 Renewing seal on right of bevel box”, page 196
2.3.1 Renewing seal on right of gearbox,

front-wheel drive vehicles
♦ Puller - T10055-

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

Removing
– Grease drill bit -3- so that metal chips adhere to it.
– Drill only through sheet metal ring -1- (about 3 mm) because
gearbox may otherwise be damaged.
– Seal drive shaft aperture on transmission with a clean cloth
-2-.
– Carefully drill a hole with a drill bit -3- (diameter 2 to 4 mm) into
outer sheet metal ring -1- of oil seal.
2. Oil seals 185

– Screw a self-tapping screw, approx. 4 mm in diameter, into

hole drilled in oil seal. Do not screw in sheet metal screw too
far to avoid damaging bearing behind it.
– Place drip tray for workshop hoist - VAS 6208- below gearbox.
– Pull out oil seal using puller - T10055- and adapter -
T10055/2- .
Note
Make sure no metal chips get into gearbox and into opening for
drive shaft. Vacuum out metal chips if necessary.
– Carefully remove cloths. When doing this, make sure that no

metal chips get into gearbox.
– Carefully clean gearbox and opening for drive shaft.
If only the sheet metal ring could be pulled out, carefully lever out
rest of seal with a screwdriver.
Installing
Install in reverse order of removal. In the process, observe the
following:
– Apply ATF to circumference and sealing lips of oil seal.
– Press oil seal in straight as far as possible by hand.

– Then check oil level and top up ⇒ page 164 .
– Grease splines -arrow- of stub shaft with universal grease -

G 060 735 A2- .
2.3.2 Renewing seal on right of gearbox, ve‐

hicles with all wheel drive

♦ Extractor hooks -T20143-
Removing
– Remove bevel box ⇒ page 35 .
– Lever out seal on gearbox using puller hook - T20143/1- or -
T20143/2- .
Installing
the following:
Before installing the seal, apply sealing grease for oil seal - G 052
128 A1- to sealing lips and cavity, and apply oil to outer circum‐
ference.
2. Oil seals 187


– Install bevel box ⇒ page 35 .

3 Components of bevel box

⇒ “3.1 Assembly overview - components of bevel box”,
page 189
⇒ “3.2 Renewing bevel box seals”, page 193
⇒ “3.3 Renewing needle bearing (polygon bearing) for stub shaft”,
page 210
3.1 Assembly overview - components of

bevel box
⇒ “3.1.1 Assembly overview - components of bevel box, 0A6”,
page 189
⇒ “3.1.2 Assembly overview - components of bevel box, 0CP”,
page 191
3.1.1 Assembly overview - components of

bevel box, 0A6
(Seals, stub shaft bearing, output flange in bevel box)
1 - Seal
❑ Between bevel box and
bevel box
❑ To renew, remove bevel
box ⇒ page 35
2 - Seal
bevel box
box ⇒ page 35
3 - Plug
❑ With captive seal
❑ 15 Nm
4 - Cap
❑ Drive in to stop with
spacer tube - VW 540
1B- .
5 - Seal
❑ For right stub shaft to
drive shaft
❑ Seal can be renewed
with bevel box installed
❑ Renewing ⇒ page 196
6 - Bevel box
⇒ page 35
7 - Cap
❑ To vent bevel box
3. Components of bevel box 189

8 - Breather pipe
❑ Press in until stop is reached
9 - Retaining ring
❑ Insert in circumferential groove in stub shaft
10 - O-ring
11 - Right stub shaft
❑ To remove and install, remove bevel box ⇒ page 35
12 - Needle bearing (polygon bearing)
❑ Needle bearing (polygon bearing) is difficult to turn with stub shaft removed. The fact it is difficult to move
does not mean that the bearing is defective. An acoustic test can only be performed with the bearings
installed.
❑ Inspect for signs of damage to bearings, such as cracking in outer race, and renew if necessary.
13 - Retaining ring
❑ For needle roller bearing (polygon bearing)
14 - Hexagon nut
❑ Removing ⇒ page 203
❑ Install using locking fluid - D 000 600-
❑ Installing ⇒ page 204
❑ 480 Nm
15 - Output flange
16 - Cover
❑ Not fitted in all bevel boxes
❑ Renew after removing output flange if damaged
❑ Engage with output flange
17 - Seal
❑ For output flange
❑ To renew, remove bevel box ⇒ page 35
18 - Bolt
❑ Tighten diagonally and alternately
❑ 25 Nm
19 - Pinion housing
❑ With shaft bevel gear and inner race/tapered roller bearing
❑ No replacement parts available for these components
❑ Carefully lever off and drive in alternately
❑ Observe bolt holes; pinion housing fits only in one position.
20 - O-ring
❑ Renew after removing pinion housing

❑ To renew, unscrew bolts ⇒ Item 18 (page 190) and carefully lever off pinion housing at projecting webs
on outside edge
❑ Do not remove hexagon nut ⇒ Item 14 (page 190) and output flange ⇒ Item 15 (page 190)
3.1.2 Assembly overview - components of bevel box, 0CP

(Seals, stub shaft bearing, output flange in bevel box)
1 - Seal
bevel box
box ⇒ page 35
2 - Seal
gearbox
box ⇒ page 35
3 - Plug
❑ With captive seal
❑ 15 Nm
4 - Seal
drive shaft
❑ Seal can be renewed
with bevel box installed
5 - Bevel box
⇒ page 35
6 - Breather pipe
❑ Press in until stop is
reached
7 - Cap
8 - Retaining ring
9 - O-ring
10 - Right stub shaft
11 - Needle bearing (polygon bearing)
❑ Needle bearing (polygon bearing) is difficult to turn with stub shaft removed. The fact it is difficult to move
does not mean that the bearing is defective. An acoustic test can only be performed with the bearings
installed.
Volkswagen Technical Site: http://vwts.ru http://vwts.info 3. Components of bevel box 191

❑ Inspect for signs of damage to bearings, such as cracking in outer race, and renew if necessary.
12 - Retaining ring
❑ For needle roller bearing (polygon bearing)
13 - Retaining ring
14 - Retaining ring
15 - Washer
16 - Output flange
17 - Seal
❑ Renew after removing output flange
18 - O-ring
❑ Renew after removing output flange
19 - Bolt
❑ 38 Nm
20 - Pinion housing
❑ With shaft bevel gear and inner race/tapered roller bearing
❑ No replacement parts available for these components
❑ Carefully lever off and drive in alternately
❑ Observe bolt holes; pinion housing fits only in one position.
21 - O-ring
❑ Renew after removing pinion housing
❑ To renew, unscrew bolts and carefully lever off pinion housing at projecting webs on outside edge.
❑ Do not remove output flange

3.2 Renewing bevel box seals

⇒ “3.2.1 Renewing left seal between bevel box and gearbox on
bevel box”, page 193
⇒ “3.2.2 Renewing seal on right of bevel box”, page 196
⇒ “3.2.3 Renewing bevel box output flange seal, 0A6, bevel box
removed”, page 200
⇒ “3.2.4 Renewing bevel box output flange seal, 0CP, bevel box
removed”, page 205
3.2.1 Renewing left seal between bevel box

and gearbox on bevel box
♦ Multi-purpose tool - VW 771/37-
♦ Removal tool - T20143-

♦ Thrust piece -T10380-
Note
Seals (Qty. 2) can be renewed only with bevel box removed. Al‐
ways renew both seals.
Removing
Remove »outer« seal.
– Lever out seal using puller hook - T20143/2- .
Remove »inner« seal.
Note
So that new seal will not be damaged later on:

– Remove retaining ring -1- from stub shaft.

– Carefully use plastic mallet -2- to drive stub shaft out in direc‐
tion of arrow.
– Pull out seal for stub shaft on gearbox side.

Installing
Drive in »outer« seal.
– Half-fill space between sealing lip and dust lip of new seal
-arrow- with sealing grease - G 052 128 A1- .
– Drive in seal to stop.

Drive in »inner« seal.

– Half-fill space between sealing lip and dust lip of new seal
-arrow- with sealing grease - G 052 128 A1- .

– Carefully use plastic mallet to drive in stub shaft to stop.
– Fit new retaining ring -1- on stub shaft.

3.2.2 Renewing seal on right of bevel box

♦ Removal tool - T20143-

♦ Hub grease cap puller - VW 637/2-
♦ Drip tray - V.A.G 1306-
♦ or drip tray for workshop hoist - VAS 6208-

♦ Sealing grease
♦ Grease for splines
♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
Note
Seal can be renewed with bevel box installed.
Removing
– Raise vehicle.
– Remove noise insulation beneath engine/gearbox ⇒ General
body repairs, exterior; Rep. gr. 66 ; Noise insulation; Assem‐
bly overview - noise insulation .

– If fitted, remove drive shaft heat shield -1- from bevel box
shaft .
The right drive shaft heat shield is secured with 2 or 3 nuts ⇒
Running gear, axles, steering; Rep. gr. 40 ; Drive shaft .
– Remove right drive shaft. ⇒ Running gear, axles, steering;
– Place drip tray or used oil collection and extraction unit - V.A.G
1782- underneath.
– Remove retaining ring -arrow A- and O-ring -arrow B- from

stub shaft.
Note
Some bevel boxes have protective cap -arrow- installed on right.

Renew protective cap each time after removing.
Pull off protective cap.
– Position hub grease cap puller - VW 637/2- in recess -arrow-

and lever off protective cap.

– Lever out seal.
Installing
– Half-fill space between sealing lip and dust lip -arrow- with
sealing grease .

– Fit new retaining ring and new seal on stub shaft.
Bevel box with protective cap
– Drive on new protective cap to stop.

– Then install retaining ring -arrow A- and O-ring -arrow B-.

– Grease splines of stub shaft using grease for clutch plate

splines .
– Install drive shaft ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shaft; Removing and installing drive shafts .
– Install heat shield -1- for drive shaft ⇒ Running gear, axles,
gr. 66 ; Noise insulation; Assembly overview - noise insula‐
tion .
3.2.3 Renewing bevel box output flange seal,

0A6, bevel box removed
The output flange is secured with a nut -A-.
Disregard -B- and -arrows-.


equipment required
♦ Support clamp - VW 313-

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


♦ Two-arm puller - VAS 251 001- or e.g. two-arm puller - Kukko
20/10-
♦ Three-arm puller - VAS 251 205- or e.g. three-arm puller -
Kukko 45-2-
♦ Extractor hook - VW 771/37-
♦ Sealing grease
♦ Universal grease
♦ Two M10×30 bolts
♦ Four M12×10 nuts
Note
The bevel box oil seal for the output flange can only be renewed
with the bevel box removed.

– Fit bevel box on gearbox support - T10108- onto hole

-arrow- marked with the number -5-.
A - Place four M12 x 10 nuts between bevel box and gearbox
support . Nuts function as spacers.
– Then align bevel box with hole opposite and secure.
– Place drip tray underneath.
– Drain oil from bevel box.
– Lock output flange for bevel box with stop plate - T10108/1- .
Screw in M10 x 30 bolts -arrows- to do this.
Removing hexagon nut for output flange

A - 36 mm socket for 3/4" drive
– Swing bevel box so that output flange points upwards.

– Pull output flange off shaft bevel gear of bevel box.
A - Three-arm puller - VAS 251 205- or e.g. three-arm puller -
Kukko 45-2-
– Pull out seal -A- for output flange.

– Clean residual locking fluid from thread of shaft bevel gear.
– Clean any oil seal residue away from area on shaft bevel gear.

Installing
– Drive in new oil seal to stop using thrust piece - T10049- .
– Half-fill space between sealing lip and dust lip with sealing
grease .
– Lightly lubricate splines of output shaft with universal grease .
– Pull in output flange using two arm puller -A-.

A - Two-arm puller - VAS 251 001- or e.g. two-arm puller - Kukko
20/10-
Please note the following:
• Use new or nearly new puller hooks!
• The output flange must not be canted.
• Fit puller hooks as far as they will go onto underside of pinion
housing.
• Take up slack on puller hooks fully with two arm puller
-arrows-.
• Puller hooks should not bend outwards.
• Interrupt pulling-on immediately when effort increases notice‐
able.
Note
♦ The puller must only open the flange so far that the nut can be
attached safely.
♦ The final position of the flange is attained by tightening the nut,
not by the puller.
Coat thread of new hexagon nut with locking fluid D 000 600
– Tightening new hexagon nut for output flange to specified tor‐
que.
Specified torque ⇒ Item 14 (page 190)
A - 36 mm socket for 3/4" drive

Measure radial run-out on output flange/shaft bevel gear.
Note
After the output flange nut has been tightened, the radial run-out
on the centring pin of the shaft bevel gear must be checked.
– Secure measuring tools with bolt -A- (M8 x 25) on bevel box.
– Fit dial gauge - VAS 6080- on centring pin of shaft bevel gear
-B- and set it to “0” with 1 mm preload.
– Turn output flange one full turn in -direction of arrow-.
– Read measured value on dial gauge.
• Max. radial run-out = 0.07 mm.
– Check gear oil level in bevel box ⇒ page 172 .
Specified torques
♦ ⇒ “3.1.1 Assembly overview - components of bevel box, 0A6”,
page 189
3.2.4 Renewing bevel box output flange seal,

0CP, bevel box removed
The output flange is secured with a retaining ring -A-.
Located behind retaining ring -A- is a washer -B-.


equipment required
♦ Support clamp - VW 313-

♦ Gearbox support - T10108-
♦ Three-arm puller - VAS 251 205- or e.g. three-arm puller -
Kukko 45-2-
♦ Extractor hook - T20143-
♦ Locking tool - T40265-
♦ Drift sleeve - 40-21-

♦ Drip tray - V.A.G 1306-

♦ or drip tray for workshop hoist - VAS 6208-
♦ Sealing grease
♦ Universal grease
♦ 2 x bolts M10 x 30
♦ 4 nuts M12 x 10
Note
The bevel box oil seal for the output flange can only be renewed
with the bevel box removed.

– Fit bevel box on gearbox support - T10108- onto hole
-arrow- marked with the number -5-.
A - Place four M12 x 10 nuts between bevel box and gearbox
support . Nuts function as spacers.
– Then align bevel box with hole opposite and secure.
– Place drip tray underneath.
– Drain oil from bevel box.
– Remove retaining ring -A- and washer -B-.

– Swing bevel box so that output flange points upwards.

– Pull output flange off shaft bevel gear of bevel box.
A - Three-arm puller - VAS 251 205- or e.g. three-arm puller -
Kukko 45-2-
– Lever out seal -A- for output flange.

• Take care not to damage the seat for the oil seal in the hous‐
ing.
– Clean any oil seal residue away from area on shaft bevel gear.
– Remove O-ring -A- from shaft.

– O-ring -A- can also be removed from shaft using a small
screwdriver.
Installing
– Place new O-ring -3- on bevel gear shaft -2- in pinion housing
-1-.

• O-ring must be located behind splines and in base of sur‐

rounding groove -arrow-.
– Drive new seal in onto limit stop.

– Half-fill space between sealing lip and dust lip with sealing
grease .
– Lightly lubricate splines of output shaft -A- with universal

grease .
– Carefully drive output flange -A- onto shaft as far as stop using
a plastic hammer.
– Fit washer -A-.

– Secure output flange in position with retaining ring -B-.
– Retaining ring -B- features an uneven contour -arrow 1-.
• Retaining ring -B- must be located in base of surrounding
groove -arrow 2-.

Measure radial run-out on output flange/shaft bevel gear.
Note
After securing the output flange, the radial run-out on the centring
pin of the shaft bevel gear must be checked.
– Secure measuring tools with bolt -A- (M8 x 25) on bevel box.
– Fit dial gauge - VAS 6080- on centring pin of shaft bevel gear
-B- and set it to “0” with 1 mm preload.
– Turn output flange one full turn in -direction of arrow-.
– Read measured value on dial gauge.
• Max. radial run-out = 0.07 mm.
– Check gear oil level in bevel box ⇒ page 172 .
Specified torques
♦ ⇒ “3.1.2 Assembly overview - components of bevel box, 0CP”,
page 191
3.3 Renewing needle bearing (polygon bearing) for stub shaft


equipment required
♦ Pressure plate - VW 401-

♦ Pressure plate - VW 402-
♦ Press tool - VW 407-
♦ Press tool - VW 412-
♦ Assembly tool - 3253/5-
♦ Tensioning device - T10047-


♦ Thrust pieces for drive pinion bearing - VW 470-
♦ Socket, multi-point bit - T10107 A-
♦ Counter-hold tool - T10371-
♦ Splitter - VAS 251 409- , or splitter 22 …75 mm , e.g. -Kukko
17/1-
♦ 2 bolts M10 x 90
♦ 2 x hexagon socket head bolts M12 x 80 with M12 nuts
Removing
– Remove noise insulation beneath engine/gearbox ⇒ General
body repairs, exterior; Rep. gr. 66 ; Noise insulation; Assem‐
bly overview - noise insulation .

– Remove retaining ring -1- from stub shaft.

– Carefully use plastic mallet -2- to drive stub shaft out in direc‐
tion of arrow.
– Align both parts of tool so that marks “B” are opposite one
another.
– The shoulders -arrows- must then be below the bearing.
– Now screw both halves together to stop.
– Lever off retaining ring -A- for needle bearing.

– To avoid damage to running surface of bearing on shaft, turn
shaft during pressing procedure -arrow-.
Installing
– Align both parts of tool so that marks “B” are opposite one
another.

– To avoid damage to running surface of bearing on shaft, turn

shaft during pressing procedure -arrow-.
– Secure needle bearing with a new retaining ring.
– Carefully use plastic mallet to drive in stub shaft to stop.
– Fit new retaining ring -1- on stub shaft.

– Install heat shield. Specified torque ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Drive shaft; Removing and installing
drive shaft .
– Check oil level in bevel box ⇒ page 172 .
tion .

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Service

Service Department. Technical Information

5.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

1.1 General safety provisions

Risk of injury and accident by accidental engagement of gear

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

Risk of irreparable damage to electronic components when

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

1.2 Safety measures when working on ve‐

Injury hazard as a result of automatic engine start in vehicles

1.3 Notes on tow-starting/towing

Danger of irreparable damage to gearbox.

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

1.4 Safety precautions when using testers

Risk of accident due to distraction and inadequate securing of

2 Rep. gr.00 - Technical data

Risk of irreparable damage to electronic components when

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

2.1 Gearbox identification

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

4 Rep. gr.00 - Technical data

3.1 General information

3.2 Rules for cleanliness

♦ If repair work cannot be performed immediately, cover opened

3.3 General repair instructions

6 Rep. gr.00 - Technical data

Oil drain and inspection plug

3.4 Gaskets and seals

3.5 Nuts and bolts

4.1 Allocation gearbox - engine

4.1.1 Passat 2015 ►, Passat Estate 2015 ►

4.1.2 Tiguan 2016 ►

Dual clutch gearbox 0DL, front-wheel drive

4.1.3 Arteon 2018 ►

4.1.4 Passat 2019 ►, Passat estate 2019 ►

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

Capacity Dual clutch gearbox 0DL

Lubricant Dual clutch gearbox oil

Capacity Front bevel box

5.1 Overview of fitting locations - electrical components

1 - Mechatronic unit for dual

10 Rep. gr.00 - Technical data

1.1 Assembly overview - dual clutch

1 - Retaining ring for dual

♦ This figure is intended only to provide an overview of the

1.2 Removing and installing clutch end cov‐

It is not always necessary to change the oil filter ⇒ page 161 .

12 Rep. gr.30 - Clutch

– Remove filter if necessary ⇒ page 161 .

The removed cover and retaining may not be installed again.

Install only a »new« cover.

Cover and retaining ring must always be renewed.

– Only handle cover as shown -in this picture-.

There must be no stickers on the inside of the cover. If stickers

– The running surface on the end of the shaft of the clutch

The centre seal of the new cover must be »preformed« before

– Clean assembly sleeve - T10459- “before using”. Do not use