D3E80219C9E-Direct Shift Gearbox

Service
Repair Manual n AG. Volkswagen AG do

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Direct Shift Gearbox
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - General, Technical Data AG. Volkswagen AG d
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30 - Clutch by
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34 - Controls, Housing ris nte
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39 - Final Drive, Differential ss c
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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.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2009 Volkswagen AG, Wolfsburg D3E80219C9E

CC 2010 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
Direct Shift Gearbox - Edition 07.2009
Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Transmission Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Transmission Component Overview . . . .Vo. l.ks.w.a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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3 Specifications . . . . . . . . . . .V.ol.ks. w.a. . . . . . . . . . . . . . . .d.oe. s.n.ot. . . . . . . . . . . . . . . . . . . . . . . . . 10
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3.1 Transmission Allocation isCodes ed . . . . . . . . . . . . . . . . . . . . . . . u.ar.an. . . . . . . . . . . . . . . . . . . . . 10
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3.2 Capacities . . . . . . .u.th. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . e.or. . . . . . . . . . . . . . . . . .
o 10
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4 Special Tools . . .s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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1.1 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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2.1 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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3 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1 Clutch Cover, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2 Clutch Cover, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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3.3 Clutch, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.4 Multi-Plate Clutch, Preparing for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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3.5 Clutch, Installing and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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34 - Controls, Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . n thi 28

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1.1 Selector Lever Cable, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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1.2 Transmission, Transporting and Securing to Assembly Stand . . . . . . . . . . . . . . . . . . . . . . 29

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1.3 Fluid Filter Changing and Fluid Level, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.1 Electric and Electronic Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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2.2 Selector Lever Manual Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.3 Selector Mechanism Overview, through 02.2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.4 Selector Mechanism Overview, from 03.2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.2 Transmission to Engine Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.1 Selector Mechanism, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.2 Selector Lever Cable, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.1 Shift Handle with Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.2 Mechatronic, Transmission Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.3 Mechatronic, Transmission Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.4 Transmission Input Speed and Clutch Oil Temperature Sensor . . . . . . . . . . . . . . . . . . . . 57
5.5 Transmission Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.6 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.7 Selector Shaft Lever Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.8 Selector Lever Cable, through 02.2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.9 Selector Lever and Mechanism with Cable, from 03.2009 . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Contents i
Direct Shift Gearbox - Edition 07.2009 AG. Volkswagen n AG do
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5.10 Transmission, Removing . . . ......... . . . . . s.ed. b.y. . . . . . . . . . . . . . . . .u.ar.an. . . . .
...... 71
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5.11 Transmission, Removing . . . ......... . . u.th.o. . . . . . . . . . . . . . . . . . . . . . . . e.e .or. .
...... 74
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5.12 Transmission, Removing . . . ......... .ss. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c.
...... 80
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5.13 Transmission, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
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5.14 Transmission, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
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5.15 Transmission, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
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6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
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39 - Final Drive, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
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1.1 Flange Shaft Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
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3.1 Left Flange Shaft and Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
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3.2 Right Stub/Flange Shaft and Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

3.3 Right Flange Shaft Needle Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
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4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
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ii Contents
00 – General, Technical Data

1 General Information
⇒ “1.1 General Repair Information”, page 1
⇒ “1.2 Troubleshooting”, page 4
⇒ “1.3 Transmission Identification”, page 6
1.1 General Repair Information

To learn more about the way the Direct Shift Gearbox (DSG), refer
to ⇒ Self Study Program No. 851403 ; The 02E Direct Shift
Gearbox Design and Function .
Tools
A complete list of special tools and equipment used in this repair
manual is listed before each repair description and in the: “Special
tools catalog”.
With smaller fasteners with a minimal tightening specification,
uncertainties often exist. Use torque wrench (5-60 Nm) -VAG
1783- for these fasteners.
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s mechatronic -J743- and/or oil pump.
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♦ If the covers are removed from the transmission or the trans‐ an
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♦ Always clean connection points and vicinity first and then loos‐
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♦ When installing the transmission, make sure the alignment

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pins are correctly seated between the engine and transmis‐

sion.
♦ Place removed parts on a clean surface and cover them so
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they do not become contaminated. Use foil and/or paper. Use

lint free cloths only!
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♦ Only install clean components: Only unpack replacement

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parts immediately prior to installation.

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♦ Carefully cover or seal unpacked components if repairs cannot

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be performed immediately.
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♦ Before installing a radial shaft seal, lubricate the sealing lips t. C rig
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circumference with DSG fluid.
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♦ Use DSG fluid only. Other lubricants cause malfunctions.
♦ The open side of the radial shaft seal faces towards the fluid.
♦ After installation, change the fluid and adjust the fluid level.
Refer to
⇒ “1.3 Fluid Filter Changing and Fluid Level, Adjusting”, page
30 .
1. General Information 1
DSG Fluid
Shake before opening.
The fluid is obtainable as a replacement part. Refer to the ⇒
electronic parts catalog for the part number.
The fluid quality is of vital importance for transmission function.
Do not use any additives. Do not fill with a different fluid.
To determine the correct fluid and other important information,
refer to ⇒ page 2 .
Drained fluid must not be used to fill again.
Caution
Be cautious when dealing with oil. Dispose of drained oil prop‐

erly. Consider this: One drop of oil makes 600 liters of drinking
water unusable.
Fluid Function
Fluid does not just lubricate the transmission.
Imagine: The fluid also transports the finest differential abrasive
parts in both filters. The fluid makes sure the lubricating film does
not wear off the differential tooth flanks. At the same time, it acts
as a switch valve pressure medium to enable it to perform its
functions.
It also seals the selector lever and helps the synchronizer rings
when shifting gears. The fluid conserves and transports warmth
and minimizes noise. The fluid performs many functions. The
DSG fluid meets very high demands!
To maintain this degree of performance,
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When To Change the
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Do not change the filter if:

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♦ The transmission oil cooler or its O-rings were replaced and

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♦ The selector shaft seal was replaced.

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♦ The flange or stub shaft seal was replaced.

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♦ Leaking mechatronic covers, multi-plate clutch or oil pump

were replaced.
♦ The transmission input speed (RPM) sensor -G182- with
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clutch oil temperature sensor -G509- was replaced.

The filter must be replaced if:
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♦ The 60,000 km maintenance interval was reached.

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♦ Coolant has entered the fluid.

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♦ Metal shavings were found in the fluid.

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♦ The clutch is burned or has a mechanical fault.

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Fluid and Fluid Level Troubleshooting

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To learn how the fluid works, refer to ⇒ page 2 . There is one thing Cop py
though the fluid cannot do: Disappear without a trace.
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2 Rep. Gr.00 - General, Technical Data

Transmission Lubricated
– Check on where the fluid has escaped from the transmission.
Repair this leak first. Fill with new fluid and check the level.
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Oil Drain and Inspection Plug -A-
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Up to transmission production date “September 20, 2004”, trans‐
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missions with two plugs were installed.
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Then the second plug was eliminated so that oil draining and ad‐
es, in part or in w
justing of the oil level is done using only plug -A-.
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A plastic overflow tube is located behind this plug (with 8 mm hex
head, tightening specification: 3 Nm). Its length determines the oil
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level in the transmission.
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Bolts and Nuts
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♦ Loosen or tighten bolts and nuts on covers or housings diag‐

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♦ The tightening specifications stated apply to non-lubricated

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♦ Clean threads of bolts that were applied with locking fluid using t. C rig
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a wire brush. Next, install bolts using locking compound -AMV yri
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185 100 A1- .
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♦ All threaded holes in which self locking bolts are threaded must
be cleaned of remaining locking fluid using a tap. Otherwise
there is a risk that the bolts will shear the next time they are
removed.
♦ Replace self locking bolts and nuts.
Electrical Components
You have probably received a electrical shock at one time, when

touching a metal item. The reason for this is the electrostatic
charge that is built up in the human body. This charge can lead
to malfunctions when contacting the electrical components of the
transmission and the gear selector.
– Touch a grounded object, for example a water pipe or a hoist,
before working on electrical components! Do not make direct
contact with connector contacts.
1.2 Troubleshooting
⇒ “1.2.1 Control Module Malfunction Behavior”, page 4
⇒ “1.2.2 Special Troubleshooting Information”, page 5
Before beginning any service work, the cause of damage should
be pinpointed using “Guided Fault Finding”.
The Guided Fault Finding is performed using the vehicle di‐
agnosis, testing and information system -VAS 5051- .
Thoughts Before Fault Finding
You should try to create a logical fault finding process.
– Make yourself aware of what kind of complaint is occurring and
what fault finding possibilities you have. Finding faults without
a logical fault finding process would not lead to success.
♦ It must also be clear: You should not find faults that others
have already found and recognize. Try to see if your problem
already had a solution described in ⇒ Technical Problem
Solving .
♦ It is possible for you to contact your Technical Support Center
(TSC). You should use this possibility! It can save you time,
effort and money.
♦ It can also be helpful to be acquainted with the Diagnostic
Trouble Code (DTC) entries from other control modules. Al‐
ways interrogate all control modules. Also, have the BUS topic
in mind during fault finding. For example, in an instance like
this ⇒ page 6 .
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1.2.1 Control Module Malfunction Behavior
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The control module works with developed software. This software

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within milliseconds. Everything modern transmission electronics

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have going for them is located in this control module. This should
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also be considered during troubleshooting.

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However, no electronics can do what they were not designed to

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do. Likewise, it is not possible to detect electronically, for exam‐

es, in part or in w
ple, where the transmission housing is leaking and fluid is escap‐

t to the co
ing. However, it is possible to detect the effects of low fluid. A

failure in gear monitoring would be recognized causing the control
module to respond that both clutches are open (no traction).
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You should know this during troubleshooting and also when work‐
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ing with the tester. It is possible that the cause for the malfunction
might not be found during Guided Fault Finding .
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In addition to updating the software, much has been done to pro‐

m
tect the transmission should there be a malfunction (safety fea‐

at
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tures). And so, when necessary, malfunctions are saved and a

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replacement program is started.

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Control module behavior during a malfunction

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If a component in the transmission malfunctions, the control mod‐

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ule reacts with a replacement function. In order to protect the Cop py
transmission, there are 4 different kinds of malfunctions:
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1- The malfunction is so minor that it is possible to continue
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driving with a replacement program while maintaining driv‐
AG.
ing safety. The driver is not notified of this via the selector
lever transmission range display -Y5- . The display shows
the selector lever position normally. When can changes in
driving behavior actually be detected.

2- Individual lever positions blink in the selector lever trans‐

mission range display. This informs the driver that this gear
can presently not be selected. An example: Reverse, lever
in “R” and vehicle drives backward. If “D” is engaged in this
situation, the letter “D” blinks in the selector lever transmis‐
sion range display. In this case, the control module prevents
1st gear from being engaged to avoid damaging the trans‐
mission. The gear is only engaged when the vehicle is
stopped. If you want to test this, do so carefully!
3- The selector lever transmission range display is completely
lit up and blinks. The selector lever position is indicated. An
example of this: Transmission oil temperature is too high.
Reasons can be, among other things: Towing a trailer with
too large of a load, auxiliary installations on front of vehicle,
lack of cooling air.
4- The selector lever position cannot be recognized. The se‐
lector lever transmission range display blinks. Differences
in the driving and shifting can definitely be felt. It is not pos‐
sible to shift into reverse. There is a serious malfunction, a
sub transmission is switched off, transmission repair is nec‐
essary. . Volkswage
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(TR) selector lever display indicates transmission is in emergency

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Check the lock washers on the selector lever cable mounting
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First click here once ⇒ page 2 .
Only add fluid if you have definitely seen: fluid is leaking. Under
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any other circumstances it is just a needless expense.
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No Faults are Stored
This especially depends on you. Experience shows that often a
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It has occurred that poor shifting behavior was a result of insuffi‐
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correctly.
Malfunctions Outside Transmission
If, for example, there is a malfunction in the transmission: “ABS
signal missing” is stored in the transmission and perhaps another
control module also says: “ABS signal missing”: Then do not con‐
tinue to suspect the transmission control module is defective.
The entry simply means: The transmission (and possibly other
control modules) is waiting for a signal via the BUS but is not re‐
ceiving it. In this case, the Anti-lock Brake System (ABS) control
module has a problem. Under no circumstances should you re‐
move the direct shift gearbox mechatronic -J743- . In this exam‐
ple, the fault points to problems with the ABS.
1.3 Transmission Identification

Example -arrow-:

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GKF - Transmission Code
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14 15 - Time
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001 - Serial Number
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On some transmissions, additional code letters are applied at the

top of the transmission in the vicinity of the selector lever cable
-arrows-.
The transmission code is also listed on the vehicle data plate.
If the vehicle data label is not available, a different transmission
was accidentally installed or there is no definite way to identify the
installed transmission, read the transmission code letters directly
from the transmission. Refer to
⇒ “1.3.1 Reading Transmission Code Letters”, page 7 .
1.3.1 Reading Transmission Code Letters

The transmission code letters are on the transmission in at least
two different locations.
On the transmission near the selector lever cable -two arrows-.

If these cannot be read or are on the head, the transmission code
letters can also be read under the right transmission mount brack‐
et.
In order to read off the code letters under the bracket directly from
the transmission, the engine with transmission must be suppor‐
ted. The left transmission mount bracket -A- must be removed.
When doing this, it is important to lower the engine/transmission
only far enough until the bracket can be slid toward the rear. If
lowered further, the pendulum support could be damaged. After
being assembled, the selector lever cable must be adjusted. Re‐
fer to ⇒ “1.1 Selector Lever Cable, Adjusting”, page 28 .
A detailed description on how to remove the bracket is not needed
here. Refer to “Transmission, Removing; Transmission, Instal‐
ling”.
Short Description
Remove the air filter and battery.
Install the engine support bridge -10-222A- and support the en‐
gine/transmission. Do not lift up.
– Remove the bolts -1 and 2- for the bracket -A-.

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– Then lower the engine/transmission slightly kswusing the engine not
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support bridge -10-222A- spindlesisuntil ara
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In most case, 2 turns of the spindles are enough to remove the

bracket -arrow-.
rrectne
– After installing the bracket, always adjust the selector lever

cable. Refer to
⇒ “1.1 Selector Lever Cable, Adjusting”, page 28 .
ss o
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2.1 Transmission Component Overview
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1 - Filter, refer to
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⇒ “1.3 Fluid Filter Changing
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❑ See ⇒ page 2 .
❑ Information on changing
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2 - Inspection Plug, refer to
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⇒ “1.3 Fluid Filter Changing

and Fluid Level, Adjusting”,
page 30 .
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❑ Near the pendulum sup‐

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3 - Drain Plug
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4 - Transmission Oil Cooler, re‐
fer to
⇒ “5.5 Transmission Oil Cool‐
er”, page 57 .
5 - Direct Shift Gearbox (DSG)
Mechatronic -J743- , refer to
⇒ “2.1 Electric and Electronic
Component Locations”,
page 34 .
6 - Transmission Input Speed
(RPM) Sensor -G182- and
Clutch Oil Temperature Sen‐
sor -G509- , refer to
⇒ “2.1 Electric and Electronic
Component Locations”,
page 34 .
7 - Oil Pump, refer to ⇒ “5.6 Oil Pump”, page 60 .
8 - Multi-Plate Clutch Cover (End Cover)
9 - Multi-Plate Clutch, refer to ⇒ “1.1 Clutch”, page 13 .
2. Description and Operation 9

3 Specifications
⇒ “3.1 Transmission Allocation Codes”, page 10
⇒ “3.2 Capacities”, page 10
3.1 Transmission Allocation Codes

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⇒ “3.1.1 GTI, MY 2006 through 2009”, page
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⇒ “3.1.2 Golf/GTI, from MY 2010”, page
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⇒ “3.1.3 Passat”, page 10 ss c
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⇒ “3.1.4 Passat CC”, page 10
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If original replacement parts are needed for a repair, always pay
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Direct Shift Gearbox 02E
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with drain plug through Sep‐ HBQ
tember 20, 2004
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without drain plug after Sep‐ HUT, HXW, JPP, KCZ, KNC,
tember 20, 2004 KPV, LQZ and LTL
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2.0L - 147 kW TFSI
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LQY, LTK
2.0L - 147 kW TFSI
3.1.4 Passat CC
LQY, LTK
2.0L - 147 kW TFSI
3.2 Capacities
Capacity Direct Shift Gearbox 02E
Initial fill in factory 6.9 to 7.2 L
depending on vehicle and trans‐
mission build date
Replacement capacity in approximately 5.2 liters
service

Capacity Direct Shift Gearbox 02E

Lubricant: DSG fluid
The fluid is obtainable as a replacement part. The replacement
part number is found in the ⇒ electronic parts catalog .
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3. Specifications 11
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Directth Shift Gearbox - Edition 07.2009
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4 Special Tools
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Special tools and workshop equipment required
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♦ Torque wrench (5-60 Nm) -VAG 1783-
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♦ Vehicle diagnosis, testing and information system -VAS 5051-
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30 – Clutch
⇒ “1.1 Clutch”, page 13
1.1 Clutch
The term clutch is not completely accurate on closer examination.
Direct Shift Gearbox (DSG) clutches always contain at least two
clutches which is why the term “multi-plate clutch” is more appro‐
priate. In this case, the clutch has two clutch disc packs - that is,
a wet clutch. The outer, larger disc pack is called “K1” (clutch 1).
“K 1” shifts the reverse gear and gears 1, 3 and 5. The inner,
smaller “K 2” (clutch 2) shifts the gears 2, 4, and 6.
Volkswagen AG
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Replacement clutches are supplied with the locking ring already
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Follow the procedure exactly to avoid rotating the components
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⇒ “3.5 Clutch, Installing and Adjusting”, page 22 .
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2 Specifications
⇒ “2.1 Fastener Tightening Specifications”, page 14
2.1 Fastener Tightening Specifications

Component Fastener Size Nm
Fluid Drain Plug - 45
Oil Filter Housing - 20
Overflow Tube - 3
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14 Rep. Gr.30 - Clutch

3 Removal and Installation

⇒ “3.1 Clutch Cover, Removing”, page 15
⇒ “3.2 Clutch Cover, Installing”, page 17
⇒ “3.3 Clutch, Removing”, page 20 lks wage es n
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⇒ “3.4 Multi-Plate Clutch, Preparing for ir se Installation”, page 21
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⇒ “3.5 Clutch, Installing and Adjusting”,
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The cover seals the transmission from the outside. It is held in
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can be pried out of its seating. The cover and circlip must always
spec
be replaced. Never install a new cover using a hammer and never
es, in part or in w
oil the center seal or touch it with your hand! If this should occur,
t to the co
the cover will certainly leak!
To perform work on the cover, the transmission must be removed.
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– Remove the transmission. Refer to
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⇒ “5 Removal and Installation”, page 45 .
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– Install the transmission to the assembly stand. Refer to

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⇒ “1.2 Transmission, Transporting and Securing to Assembly

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A plastic overflow tube is located in this hole (with 8 mm hex head,
tightening specification: 3 Nm). Its length determines the oil level
in the transmission.
– Remove this overflow tube.
– Drain the fluid.
– Hand tighten the overflow tube to 3 Nm.
– Install the drain plug -A- with a new seal.

Tightening specification: 45 Nm
3. Removal and Installation 15

– If necessary, remove the filter.

There are often uncertainties as to whether the filter must be re‐
placed or not. agen
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The information on changing the oil filter, refer to ⇒ page
ed
by 2 , can
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help when making this decision. ho
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– Install the new filter with the seat facing downward and tighten
the housing to 20 Nm.
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– After performing repairs, the filter does not need to be changed
atio
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again when filling with fluid.

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– Remove the circlip.

The cover can be pried out using a screwdriver.
Only install a new cover. Refer to
⇒ “3.2 Clutch Cover, Installing”, page 17 .

3.2 Clutch Cover, Installing

There are two types of covers.
♦ ⇒ “3.2.1 Covers Delivered without Bushings”, page 17 .

♦ ⇒ “3.2.2 Covers Delivered with Bushings”, page 19 .
AG. Volkswagen AG d
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3.2.1 Covers Delivered without Bushings

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The cover and circlip must always be replaced. Never install a

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Do not grasp a new cover in the center hole. The cover must
not be touched inside the hole, oiled or come into contact with
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any other substances in that area. Leaks would result from this.
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– Only hold the cover in your hands as shown in this illustration!

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♦ Clean the guide sleeve -T10302- “before using, and do not use
any scratched sleeves”

The new cover must be free of oil and dry in the area of the center
seal!
– Clean the end of the clutch shaft if necessary.
Do not apply adhesive to the inside of the cover.
– If this is done, carefully remove the adhesive!
Only coat the outer edge of the seal with DSG fluid.
– Place the -T10302- on a level surface.
The center seal on the new cover must now be preformed:
– Guide the cover horizontally and evenly over the entire -
T10302- . This sets the sealing lips in the installed position.
– Then remove the -T10302- upward out of the cover and place
the -T10302- on the end of the clutch shaft.
– Guide the cover horizontally over the -T10302- and press it AG. Volkswagen AG d
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It is possible to carefully pry the cover into place using a screw‐

driver, until the new circlip can be installed.
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– Install the new circlip.

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3.2.2 Covers Delivered with Bushings

The cover and circlip must always be replaced. Never install a
new cover using a hammer and never oil the center seal or touch
it with your hand!
Caution
Do not grasp a new cover in the center hole. The cover must
not be touched inside the hole, oiled or come into contact with
any other substances in that area. Leaks would result from this.
DO NOT remove the bushing!

The new cover must be free of oil and dry in the area of the center
seal!
– Clean the end of the clutch shaft if necessary.
Do not apply adhesive to the inside of the cover.
– If this is done, carefully remove the adhesive!
Only coat the outer edge of the seal with DSG fluid.
– Install the new cover with bushing.
Caution
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Handle with care. If the cover is hit inolkany
swa way, leakage will does no
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definitely occur. db
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It is possible to carefully pry the cover into place using a screw‐

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driver, until the new circlip can be installed.

spec
es, in part or in w
– Install the new circlip.

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– Only remove the bushing once the circlip has been installed.
AG. Volkswagen AG d
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3.3 Clutch, Removing
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To remove and install the clutch, the transmission must be se‐
erm
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cured in a vertical position on the assembly stand.
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– Remove the clutch cover. Refer to
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⇒ “3.1 Clutch Cover, Removing”, page 15 .
hole
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– Remove the circlip -arrow-.
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For your information: When being installed later, this circlip must
be resized and replaced.
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Caution
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Carefully remove the clutch. Make sure that the end cover or
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other parts of the clutch do not fall out; for this reason, do not
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by
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Prote AG.
– Remove the pump shaft -A-.

– The pump shaft is installed only after the installation of the new
clutch. Set the shaft aside until then.

3.4 Multi-Plate Clutch, Preparing for Instal‐

lation
Multi-plate clutch as a replacement part
1 - Multi-Plate Clutch
❑ The cover on a new
clutch is secured with a
circlip.
2 - Ten Circlips
❑ The circlips are of vary‐
ing thicknesses. They
are staggered in 0.1 mm
increments.
❑ Refer to notes regarding
this in
⇒ “3.5 Clutch, Installing
and Adjusting”,
page 22 .
3 - Cover
❑ Make sure that inner
sealing lip is not dam‐
aged, refer to
⇒ “3.2 Clutch Cover, In‐
stalling”, page 17 . A agen
AG. Volkswagen AG d
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bushing is inserted by olksw not
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the manufacturersedto pro‐
b ara
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tect the sealinghori
lips. eo
ut
Leave thisssbushing in
a ra
c
the cover.
ce
le
un
pt
an
4 - Circlip
d
itte
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rm
ab
❑ For the cover.

pe
ility
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Press on the clutch cover while removing the clutch.

nform
ercia
Clutch cover and lamella carrier lying beneath should be preven‐

m
a
com
ted from slipping out of the inner discs.

ion in
r
te o
thi
s
iva
do
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Cop py
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rig ht
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– Make sure the 4 oil seals are seated properly.

The ends of the seals should not overlap one another.
– Gently turn the seals once. They must move freely and mustn AG. Volkswagen AG do
not stick. lkswage es n
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th or
au ac
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ility
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hole
Important! Clutch Cover Location
spec
es, in part or in w
– See if there is a mark on the clutch -arrow-.
t to the co
– If there is no mark, then apply a color identification. Cover tab
should realign with this mark later.
rrectness of i
Set down clutch so that it cannot fall over.
l purpos
This prepares the clutch for installation, refer to

⇒ “3.5 Clutch, Installing and Adjusting”, page 22 .
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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rp
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o
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ng
t.
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Cop py
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by
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Prote AG.
3.5 Clutch, Installing and Adjusting
Caution
Avoid removing or lifting up the clutch pack carrier. Not even

slightly! The clutch discs could rotate themselves.
Short Description
• Transmission must be turned vertically in the assembly stand.
This is the only position in which the clutch axial play can later
be adjusted without complications.
• The transmission must be clamped secure in the holding fix‐
ture -VW 313- or in the engine and transmission holder -VAS
6095- . Refer to
Stand”, page 29 . It must not be rotated.
• The large lamella carrier is inserted in all clutch discs in the
clutch. The large lamella carrier must not slipped out of the
lowest clutch disc.
• Oil pump shaft is removed.
• Do not install any wavy circlips.
♦ Retaining bar -T10303-

– Place the -T10303- on the cover seat.
AG. Volkswagen AG d
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nl
pt
du
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erm
ab
ility
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wit
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hole
spec
– Then install the clutch, do not let it fall in.
es, in part or in w
t to the co
Do not install the -T10303- on clutch. The clutch is installed with
the cover as it was in the packaging.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
– -T10303- should be held in place by a second technician when

f
en
ng
t.
doing this. Cop
yi Co
py
ht. rig
The -T10303- remains installed there until all other work is com‐ rig ht
py by
pleted. co Vo
by lksw
cted agen
Prote AG.
Only remove the -T10303- when instructed to do so. Not right
now.
– Carefully remove the cover -arrow- from the clutch and lay it
aside.
Caution
Avoid removing or lifting up the clutch pack carrier. Not even

slightly! The clutch discs could rotate themselves.

– Find the 2 millimeter (mm) thick circlip from the circlips sup‐
plied and install it temporarily.
Perform 2 measurements before removing the circlip again.
First Measurement
• -T10303- remains installed!
– Install the universal dial gauge holder -VW 387- onto the trans‐
mission flange.
– Place the dial gauge button on the input shaft.

– Adjust the dial gauge pretension to 0.
– Lift the clutch upward until it stops and note the measurement
result.
Second Measurement
• -T10303- remains installed!
AG. Volkswagen AG d
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olksw not
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by
– Place the dial gauge button on the hub of rthe
ised large clutch pack ara
nte
carrier. ut
ho eo
ra
s a c
Dial gauge button must not rest on the circlip.
s
ce
e
nl
pt
du
– Readjust the dial gauge pretension to 0.

an
itte
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erm
ab
– Lift the clutch upward again until it stops and note this result
ility
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as well.
wit
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Now the calculation will be made to determine which of the re‐

hole
spec
maining nine circlips will be finally installed:

es, in part or in w
t to the co
– For this, use this formula:

Second measurement minus first measurement plus 1.85 mm
= thickness of the circlip to be installed
rrectness of i
– Note this result.

l purpos
The remaining nine circlips are staggered in 0.1 mm increments.

nform
ercia
– Measure all circlips and then determine the circlip which

matches your result.
m
at
om
ion
– Remove the 2 mm thick circlip and replace it with the deter‐

c
in t
or
mined circlip.
his
ate
do
riv
– Dispose of all other circlips remaining and the 2 mm thick cir‐

p
cum
or
clip.
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ng
t.
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op
Circlips must only be installed one time. C py
t. rig
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pyri by
Vo
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by c lksw
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Prote AG.

– Install the pump shaft.
AG. Volkswagen AG d
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un
pt
an
d
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ab
ility
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wit
is n
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– Install the clutch cover so that tab aligns with the mark.
ole,
spec
– Remove the -T10303- .
t to the co
– Install the clutch cover. Refer to
⇒ “3.2 Clutch Cover, Installing”, page 17 .
rrectne
This concludes the installation, the clutch is correctly adjusted.
After installing the transmission
ss o
cial p
f
– Perform a basic measurement on the DSG mechatronic -
inform
J743- .
mer
atio
m
Special Care
o
n
c
i
or
n
Installing the multi-plate clutch requires special care because: All
thi
te
sd
a
components have been balanced with each other by the manu‐

iv
o
r
facturer. Do not rotate them from their original position, otherwise

p
cum
r
fo
imbalances will occur, creating diminished shift comfort and life

en
ng
t.
yi
span.
Co
Cop py
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If clutch components slip out or clutch pack carriers were raised
rig ht
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up: by c lksw
cted agen
Prote AG.
Use light rotating motions to reposition the large, and if necessary
the small clutch pack carrier in all of the inner clutches.
The clutch cover, especially, should always be installed in the
same position, as it was when the new clutch was delivered. Refer
to ⇒ Fig. “ Important! Clutch Cover Location “ , page 22 .

1 - Multi-Plate Clutch/Clutch
Housing
2 - Oil Seal
AG. Volkswagen AG d
❑ Quantity: 4 ksw
agen oes
not
ol
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3 - Large Lamella Carrier ised b ara
nte
or
❑ Do not remove aut h eo
ra
ss c
ce
le
un
pt
Caution
an
d
itte
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Prevent the removal or
rm
ab
pe
lifting of the lamella car‐
ility
ot
rier Not even slightly!
wit
, is n
The clutch discs could
h re
hole
rotate themselves.
spec
es, in part or in w
t to the co
4 - Outer Disc
❑ Quantity: 4
rrectness of i
5 - Inner Clutch Disc
l purpos
❑ Quantity: 4
6 - Thrust Washer
nform
ercia
7 - Circlip
m
a
com
tio
❑ In the event the circlip
n in
r
te o
was removed in order to

thi
s
reinsert discs, it should
iva
do
r
be replaced with a new

rp
cum
fo
circlip of the same thick‐

en
ng
t.
yi
ness.
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8 - Circlip
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❑ This circlip must be re- Prote
cted agen
sized with each clutch
AG.
installation.
9 - Clutch Cover
10 - Circlip
❑ Always replace.
❑ Do not install any wavy circlips.

4 Special Tools
♦ Holding fixture -VW 313-
♦ Engine and transmission holder -VAS 6095-
♦ Universal dial gauge holder -VW 387-
♦ Guide sleeve -T10302-
♦ Retaining bar -T10303-
lkswage es n
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un
pt
an
d
itte
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erm
ab
ility
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wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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Cop py
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cted agen
Prote AG.
4. Special Tools 27
34 – Controls, Housing
⇒ “1.1 Selector Lever Cable, Adjusting”, page 28
Stand”, page 29
⇒ “1.3 Fluid Filter Changing and Fluid Level, Adjusting”,
page 30
1.1 Selector Lever Cable, Adjusting

Selector lever cable must always be adjusted if:
♦ Selector lever cable was removed from the transmission.
♦ Engine and/or transmission were removed and installed.
♦ Parts of transmission mount were removed and installed.
♦ Cable or shift mechanism were removed and installed.
♦ Engine/transmission positions were changed, for example, in‐
stalled free of tension.
AG. Volkswagen AG d
agen
Adjusting olksw
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not
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– Shift the selector lever orisin the vehicle to the “P” position.
e nte
eo
h
ut ra
Shift lever on transmission
ss a
in the “P” position. c
ce
le
un
Lever on transmission must be pressed all the way back.

pt
an
d
itte
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If there is any uncertainty:

rm
ab
pe
ility
– Pull the lever all the way forward.

ot
wit
, is n
h re
– Press lever back.

hole
spec
“P” is in the second detent.

es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
28 Rep. Gr.34 - Controls, Housing

– Install the cable with a loosened adjustment bolt -arrow- and

new lock washers -A and B-.
– Push the lever on the transmission back -arrow-. Bring the

transmission into the “P” position.
Note
♦ Vehicle can be raised to ensure transmission is in the “P” po‐

sition (parking slock
wageis engaged). Bothdfront
n AG. Volkswagen AG o
es n wheels must not be
able to bebyturned
Volk together in one direction. ot g
u ara
ed
♦ Thethtransmission is also in the “P” position if thetevehicle does
is n
or eo
not
s a move with wheels spinning freely.
u ra
c
s
ce
le
un
pt
– Lightly tap the selector lever button forward and backward and
an
d
itte
make sure to keep the selector lever in the “P” position.

y li
rm
ab
pe
ility
This locates the cable core in its optimal position.

ot
wit
, is n
h re
– Tighten the adjustment bolt -arrow- to 13 Nm.

hole
spec
es, in part or in w
This ends the adjustment.

t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
1.2 Transmission, Transporting and Secur‐

do
r
rp
cum
fo
ing to Assembly Stand

en
ng
t.
yi Co
op py
t. C rig
gh ht
pyri by
Vo
♦ Engine sling -2024 A-
o
by c lksw
cted agen
Prote AG.
♦ Shackle -10-222A/12-
♦ Transmission support jig -3336-
Always secure heavy parts when transporting.
Remember there is fluid in the transmission. Do not turn the
transmission with the vents facing downward when transporting
or when it is on the assembly stand. The fluid will leak out.
Transporting
– Use appropriate lifting tools, for example part of -2024A- and
-10-222A/12- (not in illustration).
The transmission can also be lifted with the -3336- .
Example: Mounting the transmission to the assembly stand
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
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un
pt
an
d
1.3 Fluid Filter Changing and Fluid Level,

itte
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erm
ab
Adjusting ility
ot p
wit
is n
The following chapter shows how to change the oil and filter to‐
h re
ole,
gether.
spec
If the old filter remains in the transmission, observe the informa‐

t to the co
tion on fluid, refer to ⇒ page 2 .

Short Description
rrectne
First, the fluid temperature is read out. If it is higher than 50 °C

(122 °F), allow the transmission to cool. With the engine off, re‐
ss
move the overflow tube and drain the fluid Then install the over‐
o
cial p
flow tube again and overfill the transmission.

inform
mer
Start the engine and drain any excess fluid until the oil level has
atio
reached the overflow tube.

om
n
c
i
or
If the fluid filter is being replaced, then it often necessary to create

thi
te
an access to the filter. The air filter housing must be removed.

sd
iva
o
pr
cum
r

fo
en
ng
t.
yi Co
♦ Vehicle diagnosis, testing and information system -VAS 5051- Cop py
ht. rig
rig ht
py by
co Vo
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30
Prote AG.
Rep. Gr.34 - Controls, Housing
olksDirect
wagen AShift Gearbox - Edition 07.2009
ag en AG. V G does
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♦ Adapter for oil filling -VAS 6262 A- sed b ara
nte
ri
ho eo
♦ Used oil collection and extractionadevice
ut -VAG 1782- or ra
c
ss
♦ Drip tray -VAG 1306-
ce
e
nl
pt
du
an
itte
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erm
ab
The fluid is obtainable as a replacement part. The replacement
ility
ot p
part number is found in the ⇒ electronic parts catalog .
wit
, is n
h re
hole
Requirements
spec
es, in part or in w
• Engine off
t to the co
• Vehicle in horizontal position, all hoist supports at same
height.
rrectness of i
• Noise insulation is removed if necessary
l purpos
• Selector level in the “P” position

• -VAS 5051- is connected
nform
mercia
• To begin working, the fluid temperature should not be higher
at
om
i
than 50 °C (122 °F).
on
c
in t
or
his
ate
do
riv

p
cum
for
It is important to not switch the plugs. Later, during an oil change,
en
ng
t.
yi
only install -A- near the pendulum support
Co
Cop py
t. rig
gh
Transmissions installed after September 20, 2004, have only one
ht
pyri by
Vo
o
plug -A-.
c by lksw
cted agen
Prote AG.
– Likewise later, before installing the plug, replace the seal

-arrow-.
– Follow the sequence of each of the following instructions until
the fluid change is completed.
Changing the fluid and filter
– Connect the -VAS 5051- and identify vehicle in GUided Fault
Finding .
– Direct Shift Gearbox Transmission
– Check Oil Level
• Let the transmission cool down if the oil temperature is higher

than 50 °C (122 °F).
– Engine off - do not start!
Only start the engine when requested to do so. Not right now.
– Place the -VAG 1306- underneath the transmission.
– Loosen the filter housing -arrow- 7 turns.
– Wait 10 seconds.
This allows the fluid to flow back into the transmission from the
filter housing.
– Remove the fluid filter housing.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
– After you have installed the filter with the shoulder downward,
y li
erm
ab
tighten the housing to 20 Nm.
ility
ot p
Wipe clean any oil.
wit
, is n
h re
hole
– Raise the vehicle.
spec
es, in part or in w
– Remove the noise insulation panel.
t to the co
– Place the -VAG 1782- or the -VAG 1306- under the transmis‐
sion.
rrectness of i
l purpos
nf
ercia
or
– Remove the inspection plug near the pendulum support
m
m
atio
-arrow-.
om
n in
or c
A black plastic overflow tube is located in this hole (with 8 mm hex thi
e
head, tightening specification: 3 Nm).

t
sd
iva
o
r
rp
cu

o
m
f
en
ng
t.
yi Co
About 5 liters of fluid will drain. t. Cop py
rig
gh ht
– Reinstall the overflow tube, 3 Nm. yri
p by
co Vo
by lksw
cted agen
Prote AG.

– Install adapter -A- from the -VAS 6262A- hand tight into the
inspection plug hole.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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Shake the bottles before opening.
erm
ab
ility
ot p
– Fill 5.5 liter DSG fluid.
wit
is n
h re
To change bottles, the shut off valve can be closed or the -VAS
ole,
spec
6262 A- can be held higher than the transmission.
t to the co
– Move through the -VAS 5051- until the DSG fluid temperature
is displayed.
– Now start the engine.
rrectne
– Press the brake and shift into each selector lever position for
s
approximately 3 seconds. Place the lever in the “P” position
s o
again.
cial p
f inform
Do not turn off the engine!
mer
atio
m
With an oil temperature of 35 to 45 °C (95 to 113 °F) :

o
n
c
i
or
n thi
– With the engine running, disconnect the quick acting coupling

te
sd
a
of the -VAS 6262A- .

iv
o
pr
cum
r
fo
– Let the excess fluid drain.

en
ng
t.
yi Co
op
– As soon as the fluid has run out (it begins to drip), remove the C py
t. rig
gh
-VAS 6262A- and install the plug with new seal.
ht
pyri by
Vo
o
by c lksw
Tightening Specification: 45 Nm cted agen
Prote AG.
– Turn off the engine.

Drained fluid must not be used again.
Dispose of the fluid in an appropriate manner, refer to ⇒ page 2 .
This completes the fluid and filter change.
Oil level in transmission is correctly adjusted.
– Install the noise insulation panel.
2 Description and Operation

⇒ “2.1 Electric and Electronic Component Locations”, page 34 lkswage es n
o ot g
byV ua
⇒ “2.2 Selector Lever Manual Release”, page 34 ir se
d ran
tee
tho
u or
⇒ “2.3 Selector Mechanism Overview, through 02.2009”,ss a ac
page 35
ce
le
un
pt
an
d
⇒ “2.4 Selector Mechanism Overview, from 03.2009”, page 37
itte
y li
erm
ab
2.1 Electric and Electronic Component Lo‐
ility
ot p
wit
cations
is n
h re
ole,
spec
The electric components are located in the transmission.
t to the co
Only the selector lever sensor system control module -J587- and
shift lock solenoid -N110- are located on the selector lever.
rrectne
1 - Direct Shift Gearbox (DSG)
Mechatronic -J743-
ss o
❑ Behind the large cover.
cial p
f inform
❑ Removing and installing
mer
with transmission instal‐
atio
m
led, refer to
o
n
c
⇒ “5.2 Mechatronic,
i
or
n thi
e
Transmission Installed”,
t
sd
va
page 46 .
i
o
pr
cum
r
fo
❑ Removing and installing
en
ng
t.
yi
with transmission re‐
Co
op py
moved, refer to
t. C rig
gh ht
yri
⇒ “5.3 Mechatronic, p by
co Vo
Transmission Re‐
by lksw
cted agen
Prote
moved”, page 52 .
AG.
2 - Transmission Input Speed

(RPM) Sensor -G182- and
Clutch Oil Temperature Sen‐
sor -G509-
❑ Before the sensor can
be removed, the mecha‐
tronic must be removed.
Refer to
⇒ “5.2 Mechatronic,
Transmission Installed”,
page 46 .
3 - Selector Lever -E313-
2.2 Selector Lever Manual Release

Do not remove the shift knob.
– Press the brake pedal or engage the parking brake.

In case of an emergency:
– Hold the leather boot and remove the trim.
Vehicles through 02.2009
– Press the yellow plastic part from right to left -arrow-.
lkswage es n
o ot g
Vehicles from 03.2009 d byV ua
ran
ir se tee
– Push down -arrow- on the yellowuth plastic piece.
o
or
ac
a
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
2.3 Selector Mechanism Overview, through

i
or
n thi
te
02.2009
sd
iva
o
pr
cum
r
fo
en
ng
t.
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WARNING
Co
Cop py
t. rig
gh ht
yri by
Shift the selector lever into the “P” position and engage the cop Vo
by lksw
parking brake before working with the engine running. cted agen
Prote AG.

1 - Shift Handle with Cover

The GTI shift handle is shown
on the left.
❑ Do not remove the shift
handle if it is not neces‐
sary. For an emergency
release, only the cover
must be removed. Refer
to
⇒ “2.2 Selector Lever
Manual Release”,
page 34 .
❑ For the shift handle on
the right: Pull the lock
button past its pressure
point before removing
the handle. Secure it
with a tie strap or with
wire. This prevents the
lock button from being
pushed back into the
handle accidentally.
❑ GTI: Do not push the
lock button in. If it is
pressed, the handle
must be removed and
prepared for installation,
refer to
⇒ Fig. “ The lock button
in the GTI handle must AG. Volkswagen AG d
not be pushed in. “ , lksw
agen oes
not
page 46 . d by
Vo gu
ara
ise nte
r
2 - Selector Lever and Mecha‐ ut
ho eo
ra
nism ss a c
ce
le
❑ With the shift lock sole‐

un
pt
noid -N110- .
an
d
itte
y li
rm
❑ Emergency release, re‐

ab
pe
ility
fer to
ot
wit
⇒ “2.2 Selector Lever Manual Release”, page 34 .

, is n
h re
❑ Short description for removal and installation:

hole
spec
es, in part or in w
– Remove the center console.

t to the co
– Remove the cable from the transmission and from the selector mechanism. Refer to
⇒ “5.8 Selector Lever Cable, through 02.2009”, page 63 .
rrectness of i
– If necessary: Disconnect or remove the exhaust system. Refer to one of the following:
l purpos
• Gas engines, refer to ⇒ Engine Mechanical, Fuel Injection and Ignition; Rep. Gr. 26 ; Description and
nform
ercia
Operation .
m
• Diesel engines, refer to ⇒ Engine Mechanical, Fuel Injection and Glow Plug; Rep. Gr. 26 ; Description and
a
com
tio
Operation .
n in
r
te o
thi
– Remove the heat shield beneath the vehicle.

s
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– Adjust the selector lever cable after installing. Refer to

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3 - Bolt with Spring, 3 Nm
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4 - Pin Prote
cted AG.
agen
❑ Removing, refer to ⇒ “5.8 Selector Lever Cable, through 02.2009”, page 63 .

❑ Do not grease

5 - Securing Plate
❑ Always replace after removing.
6 - Nut, 9 Nm
❑ Quantity: 4
7 - Shift Housing
❑ With seal
8 - Retaining Washer
9 - Retaining Washer
10 - Selector Lever Cable
❑ Do not grease the cable.
❑ Removing and installing, refer to ⇒ “5.8 Selector Lever Cable, through 02.2009”, page 63 .
❑ Checking, refer to ⇒ “4.2 Selector Lever Cable, Checking”, page 44 .
❑ Adjusting, refer to ⇒ “1.1 Selector Lever Cable, Adjusting”, page 28 .
Volkswagen AG
11 - Bolt, 8 Nm agen
AG. does
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❑ Quantity: 4 ed by V gu
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2.4 Selector Mechanism Overview, from
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03.2009
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WARNING
, is n
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spec
Shift the selector lever into the “P” position and engage parking
es, in part or in w
brake before working with the engine running.

t to the co
rrectness of i
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nform
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at
om
ion
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or
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ate
do
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1 - Shift Handle with Cover

❑ Do not remove the han‐
dle if it is not necessary.
For emergency release,
only the cover must be
removed. Refer to
Manual Release”,
page 34 .
❑ Pull the lock button past
its pressure point before
removing the handle.
Secure the lock button
with a tie strap or with
wire. This prevents the
lock button from being
pushed back into the
handle accidentally.
❑ Removing and instal‐
ling, refer to
⇒ “5.1 Shift Handle with
Cover”, page 45 .
2 - Selector Lever and Selector
Mechanism with Cable
❑ With the shift lock sole‐ AG. Volkswagen AG d
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❑ Do not grease the cable. rised ara
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❑ Removing and instal‐ aut
h
ra
ling, refer to ss c
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le

un
and Mechanism with pt

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Cable, from 03.2009”, y li

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page 70 . ab
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❑ Checking, refer to
is n
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spec
Cable, Checking”,
page 44 .
t to the co
❑ Adjusting, refer to ⇒ “1.1 Selector Lever Cable, Adjusting”, page 28 .

3 - Bolt, 8 Nm
rrectne
4 - Nut, 8 Nm
s
❑ Quantity: 4
s o
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5 - Shift Housing
nform
mer
6 - Securing Plate
atio
om

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7 - Securing Plate
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CC 2010 ➤ , Golf 2004en➤
AG,. V
Golf
olksw2009
agen A➤
G d,oGolf Plus 2005 ➤ , Golf Plus ...
ag
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- Edition 07.2009
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3 Specifications ss au ac
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⇒ “3.1 Fastener Tightening Specifications”, page 39
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⇒ “3.2 Transmission to Engine Tightening Specifications”,
erm
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page 40
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3.1 Fastener Tightening Specifications is n
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t to the co
Bolt with Spring to Selector Lever and Mechanism (through 02.09) - 3
Cable Bracket to Mechatronic Cover (Large) Nut - 10
rrectne
Fluid Drain Plug - 45
- 10
s
Mechatronic Cover (Large) Bolt 1
s o
cial p
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Oil Filter Housing - 20
inform
mer
Oil Pump Cover (Small) Bolt 1 - 8
atio
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Overflow Tube - 3
o
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Selector Lever Cable Adjusting Bolt - 13
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Selector Lever and Mechanism to Body Nut (through 02.09) - 8
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Selector Lever and Selector Mechanism with Cable to Body Bolt - 8
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Selector Shaft Lever Nut - 20
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Shift Housing to Body Nut (from 03.09) Prote
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- 8
Shift Housing to Selector Lever and Mechanism Nut (through 02.09) - 9
Transmission Input Speed and Clutch Oil Temperature Sensor Bolt - 10
Transmission Oil Cooler to Transmission Bolt - 20 + 90° turn
• 1 Tighten the bolts diagonally in multiple stages.
Mechatronic Bolt Tightening Sequence and Specification

– Install new bolts -1 through 10- hand tight.
– Tighten the bolts in the specified sequence to 5 Nm + 90° (1/4)
additional turn.
Oil Pump Bolt Variety and Tightening Specification
AG. Volkswagen AG d
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All 4 bolts with a flat head olksw not
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– Tightening specification:tho5 Nm + +90° (1/4) additional turn
ri
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es, in part or in w
t to the co
3 bolts have a flat head, the upper bolt is countersunk
rrectness of i
Tightening specification:
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♦ Countersunk bolt: 8 Nm without tightening angle (tighten with

-T10054- )
nf
ercia
or
♦ Flat head bolts: 8 Nm + +90° (1/4) additional turn
m
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3.2 Transmission to Engine Tightening
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Specifications
agen
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⇒ “3.2.1 GTI through 2009, Golf with 2.0L TDI”, page 41

⇒ “3.2.2 GTI from 2010, Passat and Passat CC”, page 42
Tightening specifications for the transmission installation can be
found here.
There is also some information on the left transmission mount.
Threaded connections that cannot be allocated directly to the
transmission are found in the corresponding assembly groups.
Example: Subframe
The subframe is a part of the chassis.
Additional descriptions are also found in ⇒ Suspension, Wheels,
Steering; Rep. Gr. 40 ; Specifications .

3.2.1 GTI through 2009, Golf with 2.0L TDI
M12 - 80 Nm
❑ If insert tool 18 mm -
T10179- is used: 65 Nm.
M10 - 40 Nm
- Arrows Point to Alignment
Pins
AG. Volkswagen AG d
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t to the co
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– Replace all left transmission mount bolts.

inform
mer
– Install all new bolts by hand.

atio
om
– Tighten the transmission mount bracket -A- to transmission

c
i
or
bolts -1- to 40 Nm + 90° additional turn.

thi
te
sd
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– When tightening the bolts -2-, the bracket can be pried into the
pr
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correct position with a screwdriver. Tightening specification:

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60 Nm +90° additional turn.
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Starter to transmission bolts. Refer to ⇒ Electrical Equipment; rig ht
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Rep. Gr. 27 ; Specifications .
co Vo
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Prote AG.
Subframe bolts must be replaced.
Subframe to body bolts. Refer to ⇒ Suspension, Wheels, Steer‐
ing; Rep. Gr. 40 ; Specifications .
3.2.2 GTI from 2010, Passat and Passat CC
M12 - 80 Nm
❑ If insert tool 18 mm -
T10179- is used: 65 Nm.
M10 - 40 Nm
- Arrows Point to Alignment
Pins
AG. Volkswagen AG d
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– Replace all left transmission mount bolts.

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– Install all new bolts by hand.

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– Tighten the transmission mount bracket -A- to transmission

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bolts -1- to 40 Nm + 90° additional turn.

hole
spec
– When tightening the bolts -2-, the bracket can be pried into the
es, in part or in w
t to the co
correct position with a screwdriver. Tightening specification:

60 Nm +90° additional turn.
Starter to transmission bolts. Refer to ⇒ Electrical Equipment;
rrectness of i

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Subframe bolts must be replaced.

Subframe to body bolts. Refer to ⇒ Suspension, Wheels, Steer‐
nform
ercia

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ate
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42
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4 Diagnosis and Testing

⇒ “4.1 Selector Mechanism, Checking”, page 43
⇒ “4.2 Selector Lever Cable, Checking”, page 44
4.1 Selector Mechanism, Checking

The starter must not be able to be operated in selector lever po‐
sitions “R”, “D” and “S”.
For speeds exceeding 5 km/h and shifting into selector lever po‐
sition “N”, the shift lock solenoid must not engage to lock the
selector lever. Selector lever can be shifted into driving gear.
For speeds below 5 km/h (almost a stand still) and shifting into
selector lever position “N”, the shift lock solenoid must only en‐
gage after approximately 1 second. Selector lever can only be
shifted out of the “N” position with the brake pedal pressed.
Selector Lever in the “P” Position and Ignition Switched On
• If the brake pedal is NOT pressed:
Selector lever is locked and cannot be shifted out of the “P” po‐
sition with the lock button pressed. Solenoid for the selector lever
lock blocks the selector lever. . Volkswage n AG d n AG
oes wage
• If the brake pedal isy Vpressed:
olks not
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Solenoid for selector
horis lever lock releases the selector lever. Se‐nte
e
lecting a driving
s aut mode is possible. Shift selector lever slowly or a
c
through from “P” to “S”; while doing this, check whether the dis‐
s
ce
le
play for the selector lever position in the instrument panel insert
un
pt
an
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matches the actual selector lever position.

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Selector Lever in the “N” Position and Ignition Switched On

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• If the brake pedal is NOT pressed:

h re
hole
Selector lever is locked and cannot be shifted out of the “P” po‐
spec
es, in part or in w
sition with the lock button pressed. Solenoid for selector lever lock
t to the co
blocks selector lever.

• If the brake pedal is pressed:
rrectness of i
Solenoid for selector lever lock releases selector lever. Selecting

a driving mode is possible.
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Selector Level in the “Tiptronic” Position

nform
ercia
• Move selector lever into the tiptronic gate:

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com
The illuminated “D” in the cover must go out. The “+” and “-” must
ion in
come on.
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The selector lever position display in the instrument cluster must

do
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rp
change from “P R N D S” to “6 5 4 3 2 1” when the selector lever

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is moved into the Tiptronic gate.

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Ignition and Lights Switched On
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The appropriate symbol is being lit up in the shift mechanism
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cover.
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Prote AG.
Transmission Range Display

Simultaneous lighting of all segments of the transmission range
selector lever display indicates transmission is in emergency run‐
ning mode.
4. Diagnosis and Testing 43

4.2 Selector Lever Cable, Checking

Short Description
Check the cable for ease of movement. The selector lever cable
must be disconnected from the transmission in order to check it
for ease of movement. Do not let the removed end touch anything.
Then selector lever is moved and finally the cable is reinstalled at
transmission.
Then, adjust the selector lever cable. Refer to
Do not grease the cable connection!
Checking
– Place selector lever in the “P” position.
– Remove the cable from the lever on the transmission.
– Move the selector lever from “P” to “S” and to “P” again several
times.
• Selector lever must have freedom of movement while doing
so.
– Adjust the cable. Refer to
AG. Volkswagen AG d
agen oes
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ab
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
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c
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or
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ate
do
priv
cum
for
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⇒ “5.1 Shift Handle with Cover”, page 45
⇒ “5.2 Mechatronic, Transmission Installed”, page 46
⇒ “5.3 Mechatronic, Transmission Removed”, page 52
⇒ “5.4 Transmission Input Speed and Clutch Oil Temperature
Sensor”, page 57
⇒ “5.5 Transmission Oil Cooler”, page 57
⇒ “5.6 Oil Pump”, page 60
⇒ “5.7 Selector Shaft Lever Seal”, G. Volk62
page
gen A
swagen AG
does
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⇒ “5.8 Selector LeversedCable, through 02.2009”, page 63 ara
ri nte
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aut and Mechanism with Cable, from 03.2009”, ra
c
page 70 ss
ce
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nl
pt
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GTI through 2009 ⇒ “5.10 Transmission, Removing”, page 71
an
itte
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GTI from 2010 ⇒ “5.11 Transmission, Removing”, page 74
ility
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Golf with 2.0L TDI Engine
wit
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⇒ “5.12 Transmission, Removing”, page 80
hole
spec
Passat ⇒ “5.13 Transmission, Removing”, page 86
es, in part or in w
t to the co
Passat CC ⇒ “5.14 Transmission, Removing”, page 91
⇒ “5.15 Transmission, Installing”, page 97
5.1 Shift Handle with Cover rrectness of i

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For all handles, there is the possibility that the lock button can be
pressed into the handle. Do not install the handle with the lock
nf
ercia
button pushed in. Refer to

rm
m
⇒ “5.1 Shift Handle with Cover”, page 45 .

atio
om
n in
c
– Pull the lock button out beyond its press point before removing.
or
thi
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sd
a
– Secure the lock button from being pressed in using a tie strap
iv
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or wire.
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t.
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– Unclip the cover.
Co
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– Push the sleeve upward and unlock the handle.

The lock button in the GTI handle must not be pushed in.
AG. Volkswagen AG d
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– If this should happen yanyway,
Vol
ksw unclip the handle trim
es n
oupward.
tg
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– Press the smallhlever
ris for the cable rod -arrow- again into the
nte
t o handle is installed.
groove beforeauthe
eo
ra
c ss
– Lock the handle again after installing it. To do this, press the
ce
le
un
pt
sleeve under the handle.

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is n
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spec
t to the co
rrectness o
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f inform
mer
atio
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– With the new handles, only the transportation safeguard has

o
n
c
to be removed. The lock button is already in the installed po‐

or
n thi
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sition.
t
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pr
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– Disconnect the connector from the cover.

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– Pull off handle upward.
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– Lock the handle again after installing it. Push the sleeve under
ht
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the handle. by c lksw
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Prote AG.
5.2 Mechatronic, Transmission Installed

♦ Oil collecting and extracting device -VAG 1782-

Removing
Always make sure that no dirt enters an open transmission.
Dirt entering can cause a transmission malfunction especially with
a open Direct Shift Gearbox (DSG) mechatronic -J743- and/or oil
pump.
In regards to contaminated oil, also observe information on
changing the oil filter. Refer to ⇒ page 2 .
The mechatronic can get stuck on the alignment pins when the
transmission is very warm. Let the transmission
Volkswa
cool down.
gen AG AG.
does agen
– Place the selector lever
Voin the “P” position.
lksw not
gu
b y ara
ed
– Disconnect the hbattery
oris ground (GND) cable with the ignition nte
e
switched off. Refer
ut to ⇒ Electrical Equipment; Rep. Gr. 27 ; or ac
sa
Removal and Installation .
s
ce
le
un
pt
– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.
an
d
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Gr. 50 ; Description and Operation .
erm
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If present:
wit
is n
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– Remove the connecting hose between the charge air cooler
ole,
and charge air tube. Refer to ⇒ Engine Mechanical, Fuel In‐
spec
jection and Ignition; Rep. Gr. 21 ; Description and Operation .
t to the co
– Remove the cable bracket from the large front transmission
cover (2 M6 nuts).
rrectne
– Release the mechatronic connector retainer by rotating and
removing the connector.
ss
– Position the lines in the cover area upward and tie up.
o
cial p
f inform
– Place the -VAG 1782- under the transmission.
mer
atio
– Remove the plug -A- near the pendulum support.

om
n
c
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or

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– Remove this overflow tube. cop Vo
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Approximately 5.0 liters of fluid will flow out. The -VAG 1782-
AG.
should remain under the transmission.

In regards to contaminated fluid, also observe the information on
changing the fluid filter. Refer to ⇒ page 2 .
– Reinstall the overflow tube, 3 Nm.
– Loosen the cover bolts -arrows- diagonally and remove them.

– Remove the cover and seal.
The small oil pump cover and large cover bolts must always be
replaced.
The large cover seal must also be replaced.

– Remove the small oil pump cover -A-.

In order to have enough free space to remove the mechatronic,
the pendulum support can be removed.
Then the transmission can be pressed down and back slightly.
Before handling the mechatronic, touch a grounded object again,
– Carefully unlock the transmission input speed (RPM) sensor -

G182- and clutch oil temperature sensor -G509- electrical
connector with a small screwdriver -1-.
– Only push on the locking mechanism with a screwdriver -1-
– Do not pry.
Do not use the screwdriver as a lever.
– Loosen the connector using another screwdriver -2-.
Be very careful. The connector locking mechanisms can break. If
this happens, replace the sensor.
Do Not Pull On the Wire!
– Remove the electrical connector.
– Remove the wire from the retaining tabs -arrows-.
AG. Volkswagen AG d
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olksw not
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– Loosen the bolts -1 through 10- in the specified order and re‐ s
ce
e
move them.
nl
pt
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erm
ab
ility
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, is n
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es, in part or in w
t to the co
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orm
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– Pull the mechatronic out of the transmission housing far

enough until the sensor arm -B- on the rear side is no longer
located in the transmission housing.
When handling the mechatronic, be particularly aware of the long
sensor arm.
– Carefully swivel the mechatronic downward.
– Store the mechatronic properly.
AG. Volkswagen AG d
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Storing the Mechatronic Properly ss c
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Caution
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Never lift the mechatronic by, or allow it to rest on, the sensor
wit
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arm.
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hole
spec
es, in part or in w
t to the co
If the sensor arm is damaged, the mechatronic must be replaced.
Installing
rrectness of i
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nf
ercia
– Carefully install the mechatronic into the transmission hous‐
orm
ing.
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– Ensure the alignment pin -A- in the transmission housing

iv
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-arrow 1- and the sensor arm -B- in the guide -arrow 2- are
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seated correctly on the transmission housing.
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The mechatronic and the transmission must be the same tem‐ . C rig
ht ht
perature. The alignment pins will not clamp during installation.
rig by
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cted
– Do not pinch the wire.
agen
Prote AG.
Really pay attention to this: Do NOT pinch the wire!

– Carefully place the mechatronic on the alignment pin -arrow-.
Make sure the sensor arm is in the installed position.
The transmission is shown in the illustration without the oil pump
cover:

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
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ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
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at
om
ion
c
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or
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ate
do
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for
en
ng
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Prote AG.
– Carefully place the mechatronic on the alignment pin -arrow-.

Make sure the sensor arm is in the installed position.
– Hold the mechatronic unit facing up. The sensor arm must not
touch the sensor wheel.
– Make sure the mechatronic unit touches correctly.

– Install new bolts -1 through 10- hand tight.

– Tighten the bolts in the specified sequence to 5 Nm + 90° (1/4)
additional turn.
– Hook the wire -A- first into the upper, and then into the lower
retaining tabs -arrows-.
– Connect and engage the electrical connector.
– Replace both O-rings, if the old mechatronic unit is being re‐

installed.
– Coat the O-rings with DSG fluid.
(A new mechatronic naturally already has new O-rings.)
– Clean the cover seal and transmission sealing surfaces.
– Ensure the correct seal seating.
– Place the cover over the mechatronic without pinching any
wires. wage
es n
olks ot g
byV ua
d ran
ir se tee
tho
u or
a ac
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un
pt
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ility
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is n
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ole,
spec
– Install new bolts -arrows- and tighten them diagonally in mul‐
tiple stages to 10 Nm. t to the co

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– Set the new oil pump cover -A- in place and tighten the bolts
-arrows- in a diagonal sequence and in multiple stages to 8
Nm.
– Install the cable bracket to the large cover and tighten the nuts
to 10 Nm.
– Connect the electrical connector to the mechatronic and en‐
gage the retainer by turning.
– If present: Install the connecting hose between the charge air
cooler and charge air tube. Refer to ⇒ Engine Mechanical,
Fuel Injection and Ignition; Rep. Gr. 21 ; Description and Op‐
eration .
– Reinstall any vehicle parts removed.
– Connect the battery ground cable. Refer to ⇒ Electrical Equip‐
ment; Rep. Gr. 27 ; Removal and Installation .
– Do not start engine!
– Change the filter if the fluid is dirty.
– Replace the DSG fluid and filter. Refer to
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– Install the noise insulation. Refer to ⇒ Body Exterior; by
dRep. Gr. ara
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50 ; Description and Operation . tho
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– Perform a basic measurement on the mechatronic.
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5.3 Mechatronic, Transmission Removed
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entering can cause a transmission malfunction especially with a
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open Direct Shift Gearbox (DSG) mechatronic -J743- and/or oil
hole
spec
pump.
es, in part or in w
t to the co
In regard to contaminated oil, also observe the information on
changing the fluid filter. Refer to ⇒ page 2 .
rrectness of i
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Up to transmission production date “September 20, 2004”, trans‐ nf
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changing the fluid filter. Refer to ⇒ page 2 . yri
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– If it is necessary, remove the filter.

There are often uncertainties as to whether the filter must be re‐
placed or not.
The information on changing the fluid filter, refer to ⇒ page 2 , can
help when making this decision.
– Remove both covers.

replaced.
The large cover seal must also be replaced.
refer to ⇒ page 3 . gen AG
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– Carefully unlock the transmission input speed (RPM) sensor -

G182- and clutch oil temperature sensor -G509- electrical
rrectness of i
connector with a small screwdriver -1-.

l purpos
– Only push on the locking mechanism with the screwdriver

-1-
nf
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– Do not pry.
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Do not use the screwdriver as a lever.

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– Loosen the connector using another screwdriver -2-.

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Be very careful. The connector locking mechanisms can break. If

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this happens, replace the sensor.

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Do Not Pull On the Wire! C py
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– Remove the electrical connector. cop Vo
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– Remove the wire from theutlower
ho clamp -arrow I-. or
a ac
ss
– Than remove from the wire from the second clamp -arrow II-
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and lay it aside. Do not kink the wire.
pt
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hole
spec
es, in part or in w
t to the co
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nform
mercia
at
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c
in t
or
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– Remove the bolts diagonally. Begin with bolt -1-.

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All 10 bolts must be replaced.

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– Remove the mechatronic.

When handling the mechatronic, be particularly aware of the long
sensor arm.
Caution
Never lift the mechatronic by, or allow it to rest on, the sensor
arm.

– Store the mechatronic properly.

Storing the mechatronic properly

Installing
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Never lift the mechatronic by, or allow it to rest d on, the sensor
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t to the co
rrectne
– Before installing, make sure that the transmission input speed
(RPM) sensor and clutch oil temperature sensor is installed.
ss o
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te
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– Replace both O-rings on the mechatronic connection if the old

mechatronic is being reinstalled.
(A new mechatronic naturally already has new O-rings)
– Coat the O-rings with DSG fluid.

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– Carefully place the mechatronic on the alignment
au
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pin -arrow-. e or
ac
Make sure the sensor arm is in the installed
ss position.
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– Do not pinch the wire.
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Really pay attention to this: Do not pinch the wire!
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t to the co
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All 10 bolts must be replaced.
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ate
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– First install all the bolts by hand.

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– Tighten all 10 bolts diagonally to 5 Nm. Then tighten 90° further

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following the same sequence. Beginning with bolt -1-. Cop py
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– Install the transmission input speed (RPM) sensor and clutch

oil temperature sensor wire first in clamp -II-. Then in clamp
-I-.
– Press the electrical connector onto the mechatronic.
replaced.

The seal for the large cover must also be replaced.

– Tighten the cover bolts diagonally to 10 Nm.
After installing the transmission
– Fill the fluid without replacing the filter. Refer to
30 .
– Perform a basic measurement on the mechatronic.
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5.4 Transmission Input Speed and Clutch s a c
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replaced together. They are coated with oil in the transmission
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near the multi-plate clutch. Before removing, the Direct Shift
spec
Gearbox (DSG) mechatronic -J743- must be removed.
es, in part or in w
t to the co
Often, the sensor wire is pulled. This damages it. If the wire was
pulled, the sensor must be replaced.
rrectness of i
Removing
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– Remove the mechatronic. Refer to

⇒ “5.2 Mechatronic, Transmission Installed”, page 46 .
nform
ercia
Do Not Pull On the Wire!

m
– Remove the bolt and carefully pry out the sensor with a screw‐
com
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driver or pliers.
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Only install the old sensor, if it is certain that:

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If this is not the case, you should install a new sensor.
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– Install the sensor coated with DSG fluid.

– Tighten the bolt to 10 Nm.
– Install the mechatronic. Refer to
⇒ “5.2 Mechatronic, Transmission Installed”, page 46 .
One special request:
Do not pinch the wire when installing the mechatronic!
5.5 Transmission Oil Cooler

♦ Hose clamps up to 25 mm dia. -3094-

Direct Shift Gearbox - Edition 07.2009 wage
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♦ Torque wrench (5-50 Nm) -VAG 1331- ris
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– Place the selector lever in the “P” position.
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– Remove the battery and battery holder. Refer to ⇒ Electrical
erm
ab
Equipment; Rep. Gr. 27 ; Removal and Installation .
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– Place a lint free cloth onto the transmission oil cooler and
is n
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transmission to absorb any leaking fluid.
ole,
spec
– Disconnect the coolant hoses using -3094- and remove them
t to the co
from the cooler.
rrectness o
cial p
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mer
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c
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– Remove the bolts -A- and remove the cooler -B-.
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Fluid must not drip into transmission! Prote AG.
Installing

– Replace the transmission oil cooler O-rings -C-.

– Mount the transmission oil cooler -B-, while doing this, pay at‐
tention to the O-rings -C-.
– Install new bolts -A- and tighten to 20 Nm + 90° (1/4) additional
turn.
– Install the coolant hoses to the transmission oil cooler and re‐
move the -3094- .
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– Install the battery and battery holder. Refer to ⇒ Electrical
rrectne

– Check the coolant level and top off coolant if necessary. Refer
ss
to one of the following:

o
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• Gas engines, refer to ⇒ Engine Mechanical, Fuel Injection and

mer
Ignition; Rep. Gr. 19 ; General Information .

atio
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• Diesel engines, refer to ⇒ Engine Mechanical, Fuel Injection

c
i
or
and Glow Plug; Rep. Gr. 19 ; General Information .

thi
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– After repairing, fill the fluid without replacing the filter. Refer to
p
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t.
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30 .
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Caution
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Prote AG.
Do not start the engine during coolant level test if the trans‐
mission fluid has not been filled yet.

5.6 Oil Pump

Important Information
To date, the experience from Volkswagen shows: The instruction
to remove the pump will not be given.
However, the wish for a description of removal and installation will
be fulfilled here.
Removing
Short Description
The oil pump can be replaced without removing the transmission.
Vehicle must be raised and any covers installed on the bottom of
the front end must be removed. Control arm to strut connection
does not need to be separated. Drive axle also does not have to
be removed. You do not need to “perform basic calibration”. Only
DSG fluid and pump cover must be replaced.
– Remove the lower part of the left front wheel housing liner.
Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Removal and Instal‐
lation .
– Place the -VAG 1782- under the transmission.
In regards to contaminated oil, also observe the information on
changing the oil filter, refer to ⇒ page 2 .
missions with two plugs were installed. agen
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A plastic overflow tube is located in this
ed
bhole
y V (with 8 mm hex head, ua
ran
tightening specification: 3 Nm) Itsholength
ris determines the oil level tee
in the transmission. au
t or
ac
ss
– Remove this over flow tube.
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– Replace the plug seal -arrow-.

t to the co
– The -VAG 1782- remains under the transmission.

rrectness o
cial p
f inform
mer
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om
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c
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60
AG.
– Remove the bolts -arrows- and remove the oil pump cover
-A-.
There is still oil in the oil pump cover.
– Remove the bolts -arrows- and remove the oil pump -1- from
the alignment pin and oil pump driveshaft.
It may be necessary to remove the upper bolt with -T10054- .
Installing
AG. Volkswagen AG d
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– Insert the oil pump input shaft -A- all the way into the
d by trans‐
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mission. Turn the input shaft while doing this. orise nte
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– A new metal seal -B- must always be used.ss c
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• The 2 alignment pins -C- must be located in the transmission
pt
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housing.
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– When positioning the oil pump, pay attention to the input shaft
ility
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splines and correct seating on the alignment pins.
wit
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Various Oil Pump Bolts
spec
es, in part or in w
t to the co
All 4 bolts -arrows- with a flat head
Tightening specification: rrectness of i
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♦ 5 Nm + +90° (1/4) additional turn

nform
mercia
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ate
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3 bolts have a flat head, the upper bolt -arrow- is countersunk

Tightening specification:
♦ Countersunk bolt: 8 Nm without tightening angle (tighten with
-T10054- )
♦ Flat head bolts: 8 Nm + +90° (1/4) additional turn
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– Set the new oil pump cover -A- in place and tightenised b the new ara
nte
bolts -arrows- in a diagonal sequence and in multiple
hor
stages eo
ut
to 8 Nm. ss a ra
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Transmission does not have fluid. You must now add new fluid
un
pt
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d
and adjust to the correct oil level.

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30 .
h re
hole
spec
– Install the left front wheel housing liner. Refer to ⇒ Body Ex‐
es, in part or in w
terior; Rep. Gr. 66 ; Removal and Installation .
t to the co
– Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr.
50 ; Description and Operation .
rrectness of i
5.7 Selector Shaft Lever Seal
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nform
ercia
♦ Sleeve -VW 423-

m
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com
tio
♦ Pulling hook -T20143-
n in
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– Remove the selector lever cable from the transmission. Refer cum
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en
to ⇒ “5.8 Selector Lever Cable, through 02.2009”, page 63 .

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– Remove he selector shaft lever nut -arrow-. t. C rig
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– Carefully pry the lever -A- from the selector shaft.
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– Pry out the seal.

– Lightly lubricate the new seal on the outer circumference.
– Fill the area between the sealing lip and dust lip halfway with
sealing grease -G 052 128- .
AG. Volkswagen AG d
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– Drive the new seal in until seated; be sure not to distort the
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nl
pt
seal.
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– Install the lever and tighten the nut to 20 Nm.
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ility
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The selector shaft lever fits on the splines only in one position.
wit
, is n
h re
– Install the selector lever cable to the transmission, refer to
hole
spec
⇒ “5.8 Selector Lever Cable, through 02.2009”, page 63 ,
es, in part or in w
and adjust.
t to the co
rrectness of i
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5.8 Selector Lever Cable, through 02.2009
nf
ercia
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atio
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Note
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or c
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After installation, the cable must be checked for ease of move‐

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ment and must be adjusted.

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– Place the selector lever in the “S” position. op Vo
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Loosen the adjustment bolt -arrow-.

– Remove the lock washers -A and B- . The lock washers must
later be replaced when adjusting cable.
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– In order to remove the cable and/or selector mechanism, the Vol
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heat shield and if necessary exhaust system components ed by gu
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must now be removed. Refer to one of the following: ho
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• Gas engines, refer to ⇒ Engine Mechanical, Fuel Injection
ss and c
Ignition; Rep. Gr. 26 ; Description and Operation .
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le
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pt
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ab
and Glow Plug; Rep. Gr. 26 ; Description and Operation .
pe
ility
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– Remove the heat shield.
, is n
h re
hole
spec
– Remove the shift housing bolts beneath the selector lever.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
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com
tion in
r
te o
thi
s
iva
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fo
en
ng
t.
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Cop py
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by c lksw
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Prote AG.
– Remove the circlip on the cable mounting bracket. Always re‐

place locking washer.

AG. Volkswagen AG d
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t to the co
rrectne
The shift housing is pushed forward on the cable.

ss o
cial p
f inform
mer
atio
om
n
c
i
or
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Prote AG.

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

cable -1-.
– Push the bolt upward at the same time with a screwdriver
-2-.
– Insert the screwdriver from underneath while pushing the lock‐

ing strap forward.
AG. Volkswagen AG d
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es, in part or in w
t to the co
rrectness of i
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nform
mercia
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tion in
r
te o
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For clarity:
♦ -1- push the strap forward
♦ -2- push the bolt upward
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ility
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t to the co
rrectness o
cial p
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mer
atio
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c
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or
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te
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Cop py
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– Remove the selector lever cable.

Remove the shift housing from the cable
Installing
Do not grease the cable.
– Route the selector lever cable making sure it is free of tension.
Attach it to the cable mounting bracket on the transmission.
Do not secure yet with the lock washers. Do not install the ball
head.

– When installing, make sure the selector lever cable is routed

correctly.
If the plate underneath is bent, there will be noises. The cable will
then flap on the plate.
– Pay attention to the plate. Push it upward into the tunnel when
installing.
– Mount the shift housing on the cable.
– Install the selector lever cable into the selector mechanism.
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es, in part or in w
t to the co
– Insert the cable into the bracket and then insert the bolt
rrectness of i
through the eye from the top

l purpos
Install the locking washer only after having checked the cable for
ease of movement. Refer to
nform
ercia
⇒ “4.2 Selector Lever Cable, Checking”, page 44 .

m
a
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tion in
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te o
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– Secure the cable with a new locking washer to the cable

mounting bracket on the selector mechanism.

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, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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fo
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ng
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Cop py
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co lksw
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Prote AG.
– Install shift housing, heat shield and exhaust system.

– Check the cable. Refer to

5.9 Selector Lever and Mechanism with Ca‐

ble, from 03.2009
Short Description
The selector mechanism and the selector lever cable cannot be
separated from each other. Both are removed at the same time.
It may be necessary to create some open space in the engine
compartment. Many times it is necessary to remove the air filter.
In the vehicle interior, it may be necessary to remove the center
console.
Note
After installation, cable must be checked for ease of movement

and must be adjusted.
– Place the selector lever in the “P” position. lkswage es n
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– Remove the selector lever handle. Refer to rised ran
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– Remove the center console. Refer to ⇒ Body Interior; Rep.
ce
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Gr. 68 ; Removal and Installation .
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Tightening specification: 8 Nm.
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– Remove the heat shield. This way removal is easier later.
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– Remove the lock washers -A and B- . The lock washers must
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later be replaced when adjusting cable.
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Loosen the adjustment bolt -arrow-.
– Put the vehicle and the transmission in “P” before installing the
cable.
– In order to remove the cable and/or selector mechanism, the
heat shield and if necessary exhaust system components
must now be removed. Refer to one of the following:

– Remove the selector mechanism.

Installation is performed in the reverse order of removal.
– Check the cable before installing it on the transmission. Refer
to ⇒ “4.2 Selector Lever Cable, Checking”, page 44 .
– Install the exhaust system components. Refer to one of the
following:
– Install the heat shield.
– Adjust the selector lever cable after installing. refer to
5.10 Transmission, Removing

Short Description
The transmission is removed downward as a unit. From above,;
The battery, air filter and starter are removed. Coolant hoses are
clamped off. The left transmission mount bracket is removed and
the engine and transmission are supported.
From below,:
The subframe is removed together with the. Vpendulum support,
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steering gear and both control arms.
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Removing the subframe is efound
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Steering; Rep. Gr. 40ut;hoRemoval and Installation . If done cor‐ eo
rectly, the subframesscan be removed and installed without the
a ra
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customer experiencing increased tire wear later. It is recommen‐
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Locating pins -T10096- are definitely needed for this.

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spec
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♦ Engine support bridge -10-222A-

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♦ Adjustment plate -3282/42A-

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♦ Adapter -10-222A/13-
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♦ Hose clamps up to 40 mm -3093-

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Do not place the vehicle on the floor after loosening the drive axle
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bolt.
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– Press the brake pedal in order to remove drive axle bolt
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-arrow- (second technician).
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mer
– Remove the entire air filter housing. Refer to ⇒ Engine Me‐
atio
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chanical, Fuel Injection and Ignition; Rep. Gr. 24 ; Removal

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i
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– Remove the battery and battery box. Refer to ⇒ Electrical

– Remove the starter. Refer to ⇒ Electrical Equipment; Rep. Gr.
27 ; Removal and Installation .
– Remove the selector lever cable from the transmission.

Use pliers to remove the washer on the cable mounting bracket.
Do not use a sharp end lever otherwise the rubber grommet on
the cable may get damaged.
Both lock washers must later be replaced when adjusting the ca‐
ble.
Remove the cable from the transmission cable mounting bracket
with great care. Do not bend.
You can also slide the cable back slightly from the cable mounting
bracket and later remove it when lowering the transmission. But
then observe the cable when lowering the transmission.
During later installation, only engage the small lock washer after
checking and adjusting cable. Refer to

– Clamp off the coolant hoses with either -3093- or -3094- and
remove them from the oil cooler.
cover (2 M6 nuts).
remove the connector.
– Remove all engine/transmission bolts. -T10179- is especially
good for this.
– Remove the filler pieces from both fender upper edges.
– Disconnect any hoses and cables in the area of the -10-222A-
lifting eye on the engine.
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– Remove the bolts -1 and 2- for the transmission mount bracket
-A-.
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– Lower the engine/transmission slightly using -10-222A- spin‐
s
dles so the bracket can be removed.
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wheel housing liner if necessary. Refer to the following:
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• Noise insulation, refer to ⇒ Body Exterior; Rep. Gr. 50 ; De‐

scription and Operation .
• Wheel housing, refer to ⇒ Body Exterior; Rep. Gr. 66 ; Re‐
moval and installation .
– Remove the drive axle from the transmission and carefully lay
aside.
Do not damage the surface of the axle. For this reason, tie straps
made out of plastic or both -T10038- are very good.
You can remove the left drive axle if you also remove the sub‐
frame.

Remove the subframe. Refer to ⇒ Suspension, Wheels, Steering;

Rep. Gr. 40 ; Removal and Installation .
Removing the subframe is found in ⇒ Suspension, Wheels,
Steering; Rep. Gr. 40 ; Removal and Installation . If done cor‐
rectly, the subframe can be removed and installed without the
– A small, additional cover plate (above right drive axle flange)

is located on the engine/transmission intermediate plate. Re‐
move this cover plate -A-.
– Align the -3282- with -3282/42A- .
– Guide the -VAG 1383A- under the transmission and support
it. Do not lift up.
The transmission is disconnected from the engine in this position.
– Remove all remaining engine to transmission bolts.
– Remove the transmission from the engine while being careful
of selector lever cable and lower transmission.
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clamped off. Before removing the subframe, the engine and trans‐
mission must be supported.
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From below,:
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The subframe is removed together with the pendulum support,

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chanical, Fuel Injection and Ignition; Rep. Gr. 24 ; Description

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– Remove the nut -arrow- and the ground wire -2-.
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This wiring harness is removed later with the subframe. This
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– Remove all upper bolts from the engine and transmission. -
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T10179- is especially good for this.
t to the co
– If the hose and cable connections are located near the engine
rrectne
lifting eyes: disconnect these now.
ss
– You must now disconnect the steering column from the steer‐
o
cial p
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ing gear.
inform
mer
Check once in ⇒ Suspension, Wheels, Steering; Rep. Gr. 48 ;
atio
m
Removal and Installation what should be considered when doing

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port bridge and therefore on the body for a long period of time.
• Wheel housing liner, refer to ⇒ Body Exterior; Rep. Gr. 66 ;
– Remove the heat shield over right the drive axle, if equipped.
Tightening specification ⇒ Suspension, Wheels, Steering;
– Remove the lower ball joint nuts -arrows- from the control
arms.
– Remove the coupling rods from the stabilizer bar.
– Remove both drive axles from the transmission and carefully
lay aside.
– Swivel the left drive axle into the wheel housing.
Do not damage the surface of the drive axles. For this reason, tie
straps made out of plastic or both -T10038- are very good.

Both drive axles are attached to the strut with the -T10038- .
– Remove the pendulum support from transmission.
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Next, the subframe is removed together by V with the pendulum sup‐
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Removing the subframe is found
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If the subframe is not secured, then an alignment will be neces‐
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sary.
spec
es, in part or in w
Secure the subframe. Refer to ⇒ Suspension, Wheels, Steering;
t to the co
Rep. Gr. 40 ; Description and Operation .
When removing the subframe:
rrectness of i
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– After removing a bolt -1-, immediately install a locating pin -

T10096- -2-.
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– After subframe has been removed, install the -T10346- by

hand.

– Secure it to longitudinal member.

(on the back of the 3 mounting point on the battery housing)
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– Support the engine and transmission. Do not lift up. Cop
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Approximately 3 rotations is sufficient to remove the bracket
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– Align the -3282- with -3282/42A- .
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– Guide the -VAG 1383A- under transmission and support it. Do
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of selector lever cable and lower the transmission.
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Transport the transmission and secure it to the assembly stand.
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Short Description
The battery, air filter and starter are removed. The steering gear
wiring harness is disconnected and freed up. This way it can be
lowered together with the subframe and the steering gear. Engine
and transmission are supported before the left transmission
mount bracket is removed.
From below,:
The subframe is removed together with the pendulum support,
Both drive axles are disconnected from the transmission and re‐
main inside the wheel bearing housings. Occasionally they will be
moved to the side, but they still remain on the vehicle.
Locating pins -T10096- are definitely needed for this.
If the subframe is not secured using the -T10096- , then a vehicle
alignment will be necessary later.


25 mm dia. -3094-
♦ Adapter -10-222A/18-
♦ Pin -3282/29-
♦ Multipoint socket -T10035-
Removing
height.
– Remove the entire air filter housing. ARefer
Volkto
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ageEngine Me‐
chanical, Fuel Injection and Glow en G.Rep.
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Gr. 24 ; Descrip‐
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– Remove the batteryuthand
o battery tray. Refer to ⇒ Electrical or
Equipment; Rep.ssGr. 27 ; Removal and Installation .
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27 ; Removal and Installation .

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Both lock washers must later be replaced when adjusting the ca‐
ble.
checking and adjusting the cable. Refer to
remove them.
cover (2 M6 nuts).
remove connector.
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– Disconnect the wiring harness that comes from the bottom of
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– Remove the nut -1- and cable from the E-box.

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– Remove the nut -arrow- and ground wire -2-.

– Disconnect the connector -3-.
This wiring harness is removed later with subframe. In this way,
you avoid time consuming work on the steering gear and heat
shield.
– Remove all engine/transmission bolts.
– You must now disconnect steering from steering column.

Check once in ⇒ Suspension, Wheels, Steering; Rep. Gr. 48 ;
Removal and Installation what should be considered when doing
so.
Always move the steering wheel into the center position. Engage
the steering wheel lock. Information regarding tightening the bolts
is also contained here.
– Disconnect the steering column from the steering gear.
– Support the engine and transmission. Do not lift up.
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– Remove all bolts -1 and 2- for the transmission mount bracket
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– Lower the engine/transmission slightly using the -10-222A- Prote AG.
and spindles so the bracket can be removed.

A maximum of 4 rotations is sufficient to remove the bracket

-arrow-.
• Wheel housing liner, refer to ⇒ Body Exterior; Rep. Gr. 66 ;
– Remove the heat shield over the right drive axle, if equipped.
Tightening specification, refer to ⇒ Suspension, Wheels,
Steering; Rep. Gr. 40 ; Specifications .
– Remove the drive axle from transmission and carefully lay
aside.
Next, the subframe is removed together with the pendulum sup‐

port, both control arms and steering gear.
You can find valuable information about removing the subframe
in ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Removal and
G. Volkswagen AG d
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transmission.
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– A small, additional cover plate (above the right drive axle

flange) is located on the engine/transmission intermediate
plate. Remove this cover plate -A-.
– Align the -3282- with the -3282/42A- .
– Guide the -VAG 1383A- under transmission and support it. Do
not lift up.
– Remove the transmission from engine while being careful of
selector lever cable and lower the transmission.
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Transport the transmission and secure itVoto ageassembly
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♦ Insert tool 18 mm -T10179- Prote AG.
♦ Pin -3282/29-
25 mm dia. -3094-
♦ Engine support device -3300A-
Removing
height.
and Installation .
– Remove the intake hose from the turbocharger so that the rear
eye for suspending the engine is accessible.

– Remove the battery and battery box bolts -arrows-. Refer to

⇒ Electrical Equipment; Rep. Gr. 27 ; Removal and Installa‐
tion .
– Remove the upper starter bolt.
– Remove the selector lever cable -arrows- from the transmis‐ n AG. Volkswagen AG
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Remove the cable from transmission cable mounting bracket with
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During installation later, only engage the small lock washer after
rrectness of i
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– Seal off the coolant hoses with either -3093- or -3094- and
remove them.
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remove the connector.
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– Remove the cable bracket from the black (front) transmission

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cover (2 M6 nuts).
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Use the following tools:

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wheel housing liner, if necessary. Refer to ⇒ Body Exterior;

– Remove the connecting hose -arrows- between the charge air

cooler and charge air tube. Refer to ⇒ Engine Mechanical,
Fuel Injection and Ignition; Rep. Gr. 21 ; Description and Op‐
eration .
– Remove the fan shroud -arrow-.
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– Disconnect the electrical connectortho-1- from the oil level ther‐
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– Remove the exhaust system suspended mount bolts

-arrows- from the subframe .
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– Disconnect the exhaust system at the double byV
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– Tie up the front exhaust pipe or ulay
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– Remove the left coupling rod form
s the control arm and move
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– Remove the ball joint nuts -arrows- from the left control arm.
rrectness of i
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lay aside.
– Move the left drive axle into the wheel housing and on the lon‐
nform
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gitudinal member. By doing so, the drive axle will not interrupt
m
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a
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tion in
Do not damage the surface of the axle shafts. For this reason, tie
r
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wraps made out of plastic or both -T10038- are very good.
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– Remove the heat shield bolts -arrows- and shield from over copy Vo
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the right drive axle, if equipped. Tightening specifications, re‐ cted agen
Prote AG.
fer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Speci‐
fications .
Both drive axles are attached to the struts with the -T10038- .

– Remove the left front level control system sensor -G78- nut
-arrow- from the control arm.
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– Remove the pendulum support bolts -1, 2 and 3-. ot p
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– Remove the right heat shield -1- bolt from the subframe.
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– Tighten the -T10346- with an appropriate bolt -2-.
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Bolt -2- = M6 X 20
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cted AG.
agen
not push it yet!
– If the hose and cable connections are located near the engine
lifting eyes: disconnect these now.
– Support the engine and transmission with -10-222A- and
-10-222A/8- . Do not lift up.
– Remove the transmission mount and bracket bolts -1 and 2-

for the bracket -A-.
– Lower the engine/transmission slightly over -10-222A- spin‐
dles so the bracket can be removed.

A maximum of 6 rotations is sufficient to remove the bracket

-arrow-.
– Remove the lower starter bolt and remove the starter.
It is easier to remove the starter from above. Lower the vehicle.
Perform the next step from above.
– Remove the screw in starter hole.
– A small, additional cover plate (above the right drive flange) is

located on the engine/transmission intermediate plate. Re‐
– Lower the engine with transmission until enough clearance is
available for removal between the upper edge of the trans‐
mission and left longitudinal member.
– Align the -3282- with the -3282/42A- .
the transmission. Do not lift up.
– Carefully press the engine/transmission forward.
Note AG. Volkswagen AG d

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When moving the engine/transmission
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hoses and radiator. nte
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of selector lever cable and lower the transmission.

du
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Transport the transmission and secure it to the assembly bracket.

ab
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Refer to
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♦ Engine support bridge -10-222A- cop Vo
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♦ Engine support adapter -10-222A/3-

♦ Adapter -10-222A/18-
25 mm dia. -3094-
Removing
height.
– Remove the left front wheel.
and Installation .
– Disconnect the battery. Refern AtoG.⇒VoElectrical
lkswagen AGEquipment; Rep.
Gr. 27 ; Removal and olkInstallation
swage . does
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– Remove the battery
ris
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ran to
tee
⇒ ElectricalutEquipment;
ho Rep. Gr. 27 ; Removal and Installa‐ or
tion . ss
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Note
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Later, when installing the transmission, it is possible to make sure

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the transmission ventilation cap fits properly.

h re
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es, in part or in w
– Disconnect the ground cable from the bracket.

t to the co
– Remove the starter motor. Refer to ⇒ Electrical Equipment;

rrectness of i
It is advisable to remove the lower bolt first.

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remove connector.
nf
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– Remove the cable bracket from the black front transmission

rm
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cover (2 M6 nuts).
atio
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– Remove the selector lever cable -arrows- from Volthe transmis‐
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Use pliers to remove the washer on theaucable
th mounting bracket. ra
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– Clamp the coolant hoses with either -3093- or -3094- and re‐
move them.
nform
ercia
These tools are suitable for this:

m
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or
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♦ -T10035-
♦ -T10061-
♦ -T10099-
♦ -T10179-
wheel housing liner if necessary. Refer to ⇒ Body Exterior;
– Disconnect the electrical connector -1- from the oil level ther‐
mal sensor -G266- .

– Remove the exhaust system suspended mount bolts

-arrows- from the subframe.
– Disconnect the exhaust system at double clamp -arrows-.

– Tie up the front exhaust pipe or lay is on the tunnel bridge.
AG. Volkswagen AG d
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– Remove the heat shield bolts -arrows- and shield from over
ility
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the right drive axle, if equipped. Tightening specification. Refer
wit
to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Specifica‐
is n
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tions .
ole,
spec
t to the co
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mer
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– Remove the left front level control system sensor -G78- nut
om
-arrow- from the control arm, if equipped.

n
c
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– Remove the left coupling rod form the control arm and move
t
sd
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it to the side.
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pr
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by c lksw
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Prote AG.

– Remove the left ball joint lower nuts -arrows- from the control
arm.
lay aside.
– Move the left drive axle into the wheel housing and on the lon‐
gitudinal member. By doing so, the drive axle will not interrupt
further work.
Do not damage the surface of the axle shafts. For this reason,
either plastic tie wraps or -T10038- are very good.
Both drive axles are attached to the struts with the -T10038- .
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– Remove the pendulum support bolts -1, 2 and 3-.

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– A small, additional cover plate (above the right drive flange) is

nform
ercia
located on the engine/transmission intermediate plate. Re‐

m
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ate
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Cop py
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rig ht
py by
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cted agen
Prote AG.

– Remove the right heat shield -1- bolt from the subframe.
– Tighten the -T10346- with an appropriate bolt -2-.
Bolt -2- = M6 X 20
– Secure the -3300A- to the bracket -T10346- .
– Place a cloth between the -3300A- and the engine.
If possible, place the -3300A- against the engine crankcase. Do
not push it yet!
AG. Volkswagen AG d
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– Support engine and transmission. Do not lift up.

Do not place the engine support bridge on the fender.
nform
ercia
– Support the engine and transmission with -10-222A- and

m
at
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-10-222A/10- . Do not lift up.

on
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Rep. Gr.34 - Controls, Housing Prote
cted AG.
agen
– Remove the transmission mount and bracket bolts -1 and 2-

for the bracket -A-.
– Lower the engine/transmission slightly over -10-222A- spindle
so the bracket -A- can be removed.
AG . Volkswagen AG
It really only needs to be lowered a little. As soon as the bracket
ksw
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longitudinal member later. Add a maximum of 2 turns ris
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Remove the bracket -arrow-.
wit
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– If necessary, remove the bracket with secondary pump and
spec
lay pump aside.
es, in part or in w
t to the co
– Now remove all bolts except one between engine and trans‐
mission.
rrectness of i
It is advisable to leave a bolt that is easily accessible.
l purpos
– Lower the engine with transmission until enough clearance is

available for removal between the upper edge of transmission
and left longitudinal member.
nform
ercia
– Align the -3282- with -3282/42A- .

m
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the transmission. Do not lift up.
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ate
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– Remove the transmission from the engine while being careful ht. rig
rig ht
of the selector lever cable and lower the transmission. py by
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cted agen
Prote AG.
Note
When moving the engine/transmission assembly, pay attention to

the connected lines, hoses and radiator.
Transport the transmission and secure it to the assembly bracket.

Refer to
Stand”, page 29 .
5.15 Transmission, Installing

Installation is performed in the reverse order of removal. Howev‐
er, important steps should be named here:
– Inspect the needle bearing in the crankshaft. If it is damaged
or has blue tarnish, it must be replaced. Refer to one of the
following:
Ignition; Rep. Gr. 13 ; Removal and Installation .
and Glow Plug; Rep. Gr. 13 ; Removal and Installation .

– If it is not damaged, lubricate the bearing lightly with high tem‐

perature grease -G052133A2- .
– Transmission pins (not splines) must also be lightly lubricated.
– Make sure the alignment pins are seated correctly between
the engine and transmission.
– Check correct seating of the intermediate plate.
Engine and transmission must be brought together by hand until
both flanges touch all around!
If this is not the case, it will not run correctly!
– Adjust the transmission mount until the engine and transmis‐
sion are aligned.
– Guide the selector lever cable into the cable mounting bracket
as soon as possible.
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does gen AG
Check cable when raisingVol
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wa transmission. Do not fail
not to place it
in the cable mounting
ed bracket early.
by gu
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or
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th cable. eo
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– Selector lever cable lock washers must be reconditioned.

un
pt
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– Always adjust selector lever cable. Refer to
erm
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ility
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– Check the coolant level and fill if necessary. Refer to .

h re
ole,
spec

Ignition; Rep. Gr. 19 ; General Information .

t to the co

and Glow Plug; Rep. Gr. 19 ; General Information .
rrectne
Tightening specifications, refer to

⇒ “3.2 Transmission to Engine Tightening Specifications”,
s
page 40 .
s o
cial p
f inform
mer
atio
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c
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Prote AG.

6 Special Tools
♦ Adapter for oil filling -VAS 6262 A-
♦ Used oil collection and extraction device -VAG 1782-
♦ Drip tray -VAG 1306-
♦ Hose clamps up to 40 mm -3093-
♦ Pin -3282/29-
♦ Adapter -10-222A/13-
♦ Socket, multipoint bit XZN 14 -T10061-
♦ Bits -T10099-
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♦ Vehicle diagnosis, testing and information system -VAS 5051-

spec
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t to the co
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l purpos
nform
mercia
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c
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ate
do
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6. Special Tools 99
AG. Volkswagen AG d
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♦ Hose clamps up to 25 mm dia. -3094- byV
ol not
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♦ Sleeve -VW 423-
l purpos
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♦ Pulling hook -T20143-
by lksw
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♦ Locating pins -T10096-
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♦ Bracket -T10338- nf
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6. Special Tools 101

Special tools and workshop

equipment required
♦ Engine support bridge
-10-222A-
♦ Adjustment plate
-3282/42A-
♦ Adapter -10-222A/18-
♦ Engine support adapter
-10-222A/3-
♦ Transmission support
-3282-
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39 – Final Drive, Differential

1 Description and Operation
⇒ “1.1 Flange Shaft Assembly Overview”, page 103
1.1 Flange Shaft Assembly Overview

The flange shaft is disassembled
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❑ Always replace.
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❑ Do not remove the bolts

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same time.
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2 - Flange Shaft
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3 - Protective Ring
hole
spec
❑ Removal and installa‐
es, in part or in w
tion, refer to
t to the co
⇒ Fig. “ Flange Shaft
Protection Ring, Re‐
moval and Installation “ ,
rrectness of i
page 104 .
l purpos
4 - Spring
5 - Thrust Washer
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6 - Tapered Ring
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7 - Securing Ring
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Flange Shaft Protection Ring, Removal and Installation

– Press the protection ring on by hand all the way.
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104 Rep. Gr.39 - Final Drive, Differential

olksw
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2 Specifications
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⇒ “2.1 Fastener
ss Tightening Specifications”, page 105 c
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2.1 Fastener Tightening Specifications
du
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Flange/Stub Shaft Bolt 1 - 30
h re
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spec
• 1 Always replace
es, in part or in w
t to the co
rrectness of i
l purpos
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⇒ “3.1 Left Flange Shaft and Seal”, page 106
⇒ “3.2 Right Stub/Flange Shaft and Seal”, page 107
⇒ “3.3 Right Flange Shaft Needle Bearing”, page 109
3.1 Left Flange Shaft and Seal

♦ Slide hammer-complete set -VW 771-
♦ Puller -VW 771/37-
♦ Thrust piece -3305-
♦ Torque wrench (5-50 Nm) -VAG 1331- agen
AG. Volkswagen AG d
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♦ Torque wrench (40-200 Nm) -VAG 1332- byV gu
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– Remove the wheel.

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– If installed, remove the center and left part of the insulation
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below the engine/transmission.
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– Turn the steering wheel fully to the left lock.
hole
spec
es, in part or in w
– Remove the drive axle bolts from the flange shaft.
t to the co
– Mark the installed position of the lower ball joint bolts/nuts
-1-.
rrectness of i
– Remove the bolts/nuts -1-.
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– Tie up drive axle as high as possible. Do not damage the paint

on the drive axle when doing so.
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– Place a drain pan underneath transmission.

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– Remove the flange shaft bolt, by installing two bolts in the C py
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– Remove the flange shaft with spring. cted agen
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– Remove the flange shaft seal using -VW 771- and -VW
771/37- .
Installing
– Drive the new seal in until seated using -3305- ; be sure not to
distort the seal.
– Install the flange shaft.
– Install a new flange shaft bolt and tighten it to 30 Nm.
– Install the control arm to the ball joint studs at the old impres‐
sion and tighten with new bolts/nuts. Refer to ⇒ Suspension,
Wheels, Steering; Rep. Gr. 40 ; Specifications .
– Install the left drive axle to the flange shaft. Refer to ⇒ Sus‐
pension, Wheels, Steering; Rep. Gr. 40 ; Removal and In‐
stallation .
– Install the left front wheel housing liner. Refer to ⇒ Body Ex‐
terior; Rep. Gr. 66 ; Removal and Installation .
– Install the left wheel. Refer to ⇒ Suspension, Wheels, Steer‐
ing; Rep. Gr. 44 ; Specifications
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– Check the fluid level.edRefer
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⇒ “1.3 Fluid FilterhChanging
oris and Fluid Level, Adjusting”, page nte
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3.2 Right Stub/Flange Shaft and Seal

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♦ Pressure piece -3377-

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♦ Sealing grease -G 052 128 A1-

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♦ Grease -G 052 735-

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– Remove the right wheel.

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– Remove the right drive axle. Refer to ⇒ Suspension, Wheels,

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Vehicles with a Intermediate Shaft

– After removing the right drive axle -A-, remove the intermedi‐
ate shaft -B- bolts -arrows- from the mounting bracket -C- and
pull the intermediate shaft from the stub shaft.
Continuation for All Vehicles
– Place a drain pan underneath the transmission.
– Remove the stub/flange shaft bolt -arrow-.

– Remove the stub/flange shaft together with the compression
spring.
– Remove the seal.
Installing
– Lightly lubricate the new seal on the outer circumference.
– Drive in the new seal until seated using -3377- ; be sure not to
distort the seal.
– Install the stub/flange shaft.
– Install a new stub/flange shaft bolt and tighten it to 30 Nm.
Vehicles with a Intermediate Shaft
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– Replace the O-ring on the stub shaft. yV
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– Grease the splines on the stub shaft using grease
horis for clutch tee
disc splines -G 000 100- . aut or
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– Guide the intermediate shaft -B- through the mounting bracket

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-C- onto the transmission stub shaft.

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– Tighten the intermediate shaft to mounting bracket bolts

hole
-arrows-. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr.

spec
es, in part or in w
40 ; Specifications .
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Continuation for All Vehicles

– Install the right drive axle. Refer to ⇒ Suspension, Wheels,
rrectness of i
Steering; Rep. Gr. 40 ; Removal and Installation .

l purpos
– Install the right wheel. Refer to ⇒ Suspension, Wheels, Steer‐

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Rep. Gr.39 - Final Drive, Differential
3.3 Right Flange Shaft Needle Bearing

♦ Thrust plate -VW 401-
♦ Punch -VW 407- agen
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♦ Thrust disc -VW 412- ed b y gu
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♦ Assembly tool -T10047-
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Procedure
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⇒ “3.2 Right Stub/Flange Shaft and Seal”, page 107 .
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– Install the -T10047- so that the marks “B” on both parts of the
spec
tool face each other.
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• The sections -arrows- must then be located under the bearing.
– Secure both parts together until they stop.
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– Remove the circlip -A- for the bearings.

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– Turn the shaft -arrow- while removing. This way the bearing
running surface on the shaft will not get damaged.
– Secure the bearing with a new circlip.
– Install the right flange shaft. Refer to
⇒ “3.2 Right Stub/Flange Shaft and Seal”, page 107 .

4 Special Tools
♦ Pressure piece -3377- lkswage es n
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equipment required
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♦ Slide hammer-complete set
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-VW 771-
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♦ Puller -VW 771/37-
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♦ Thrust piece -3305-
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♦ Torque wrench (5-50 Nm) -
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equipment required
♦ Punch -VW 407-
♦ Thrust disc -VW 412-
♦ Wheel bearing assembly
set -3253-
♦ Assembly tool -T10047-
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4. Special Tools 111

Cautions & Warnings
Please read these WARNINGS and CAUTIONS before proceeding with maintenance
and repair work. You must answer that you have read and you understand these
WARNINGS and CAUTIONS before you will be allowed to view this information.
•= If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we
suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially urge
you to consult an authorized Volkswagen retailer before beginning repairs on any vehicle that may still be covered
wholly or in part by any of the extensive warranties issued by Volkswagen.
•= Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical
system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.
•= Volkswagen is constantly improving its vehicles and sometimes these changes, both in parts and specifications,
are made applicable to earlier models. Therefore, part numbers listed in this manual are for reference only. Always
check with your authorized Volkswagen retailer parts department for the latest information.
•= Any time the battery has been disconnected on an automatic transmission vehicle, it will be necessary to
reestablish Transmission Control Module (TCM) basic settings using the VAG 1551 Scan Tool (ST).
•= Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose. Do not support
a vehicle on cinder blocks, hollow tiles or other props AG. Volkswagen AG dunder continuous load. Never work under a
agenthat may crumble oes
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vehicle that is supported solely by a jack. Never
by V work under the vehicle while the
gu engine is running.
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•= For vehicles equipped with an anti-theft
aut radio, be sure of the correct radio activation code
or
ac before disconnecting the
ss
battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and
ce
le
un
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become inoperable, even if the correct code is used in a later attempt.
an
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•= If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to
ility
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keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
wit
is n
starting the vehicle while you are under it. h re

ole,
spec
•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
t to the co
others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from
being fully alert.
rrectne
•= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
ss
•= Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear
o
cial p
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goggles, gloves and other protective clothing whenever the job requires working with harmful substances.
nform
mer
atio
•= Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near
om
n
c
machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe
i
or
n thi
e
injury could result.

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•= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used
en
ng
t.
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only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
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washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners withgh
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new parts where indicated, and any other time it is deemed necessary by inspection. p by
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Page 1 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
Cautions & Warnings
•= Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the vehicle.
Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled
fuel or oil.
•= Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by
grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust.
Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may result in death.
•= Finger rings should be removed so that they cannot cause electrical shorts, get caught in running machinery, or be
crushed by heavy parts.
•= Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the
instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only
replacement parts meeting Volkswagen specifications. Makeshift tools, parts and procedures will not make good
repairs.
•= Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that
might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at
once, but do not store the oily rags, which can ignite and burn spontaneously.
•= Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten
fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque
listed.
•= Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is
ignited, it will ignite gas trapped in the cells and cause the battery to explode.
•= Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of
the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that
govern the disposal of wastes.
•= The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should be
serviced only by trained automotive service technicians using approved refrigerant recovery/recycling equipment,
trained in related safety precautions, and familiar with regulations
AG. governing
Volkswagen Athe
G dodischarging and disposal of
agen es n
automotive chemical refrigerants. olksw ot g
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rise tee
•= Before doing any electrical welding on vehiclestho equipped with anti-lock brakes (ABS), disconnect
or the battery
au ac
negative terminal (ground strap) and the ABS
ss control module connector.
ce
e
nl
pt
du
an
•= Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase
itte
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system pressure and may cause the system to burst.

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•= When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission
h re
Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these
hole
spec
components is not separately fused, disconnect the control module connector(s).

es, in part or in w
t to the co
•= Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that
automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device.
rrectness of i
Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal
injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians
l purpos
should test, disassemble or service the airbag system.

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Page 2 of 3
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Cautions a& Warnings
gen AG
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•= Do not quick-charge the battery se
(for boostoristarting) for longer than one minute, and ado teenot exceed 16.5 volts at the
th
battery with the boosting cables attached.
au Wait at least one minute before boosting the obattery
ra a second time.
ss c
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un
•=
pt
Never use a test light to conduct electrical tests of the airbag system. The system must only be tested by trained
an
d
itte
Volkswagen Service technicians using the VAG 1551 Scan Tool (ST) or an approved equivalent. The airbag unit
y li
erm
ab
must never be electrically tested while it is not installed in the vehicle.
ility
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•= Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been
h re
ole,
inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair
spec
area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the
t to the co
tire from the rim before attempting any repair.
•= When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or lap while the
rrectne
vehicle is in motion. Objects between you and the airbag can increase the risk of injury in an accident.
ss o
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f in
I have read and I understand these Cautions and Warnings.
form
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Page 3 of 3
the prior expressed written permission of the publisher.
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Service

Repair Manual n AG. Volkswagen AG do

Scirocco 2009 ➤ , Touran 2003 ➤

CCT CBF BUB CBE

Service Department. Technical Information

All rights reserved.

Copyright © 2009 Volkswagen AG, Wolfsburg D3E80219C9E

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

2.1 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . n thi 28

1.1 Selector Lever Cable, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

1.2 Transmission, Transporting and Securing to Assembly Stand . . . . . . . . . . . . . . . . . . . . . . 29

1 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

3 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

3.2 Right Stub/Flange Shaft and Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

00 – General, Technical Data

1.1 General Repair Information

♦ When installing the transmission, make sure the alignment

pins are correctly seated between the engine and transmis‐

they do not become contaminated. Use foil and/or paper. Use

♦ Only install clean components: Only unpack replacement

parts immediately prior to installation.

♦ Carefully cover or seal unpacked components if repairs cannot

♦ No matter what kind of seals they are, they must always be

Be cautious when dealing with oil. Dispose of drained oil prop‐

Do not change the filter if:

♦ The transmission oil cooler or its O-rings were replaced and

no coolant has gotten into the fluid.

♦ The selector shaft seal was replaced.

♦ The flange or stub shaft seal was replaced.

♦ Leaking mechatronic covers, multi-plate clutch or oil pump

clutch oil temperature sensor -G509- was replaced.

♦ The 60,000 km maintenance interval was reached.

♦ Coolant has entered the fluid.

♦ Metal shavings were found in the fluid.

♦ The clutch is burned or has a mechanical fault.

Fluid and Fluid Level Troubleshooting

2 Rep. Gr.00 - General, Technical Data

Up to transmission production date “September 20, 2004”, trans‐

missions with two plugs were installed.

justing of the oil level is done using only plug -A-.

Bolts and Nuts

♦ Loosen or tighten bolts and nuts on covers or housings diag‐

♦ The tightening specifications stated apply to non-lubricated

nuts and bolts.

You have probably received a electrical shock at one time, when

The control module works with developed software. This software

has the ability to execute electrical functions, monitor and control

within milliseconds. Everything modern transmission electronics

also be considered during troubleshooting.

However, no electronics can do what they were not designed to

do. Likewise, it is not possible to detect electronically, for exam‐

ple, where the transmission housing is leaking and fluid is escap‐

ing. However, it is possible to detect the effects of low fluid. A

In addition to updating the software, much has been done to pro‐

tect the transmission should there be a malfunction (safety fea‐

tures). And so, when necessary, malfunctions are saved and a

replacement program is started.

Control module behavior during a malfunction

If a component in the transmission malfunctions, the control mod‐

4 Rep. Gr.00 - General, Technical Data

2- Individual lever positions blink in the selector lever trans‐

(TR) selector lever display indicates transmission is in emergency

running mode. The vehicle does not drive in reverse.