VW Amarok 8 Speed Automatic Gearbox 0dr Eng

Service
Workshop Manual
Amarok 2017 ➤
8-speed automatic gearbox 0DR
Edition 08.2020
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
32 - Torque converter
37 - Controls, housing
38 - Gears, control
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.
Amarok 2017 ➤
8-speed automatic gearbox 0DR - Edition 08.2020
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 1
1.3 Safety precautions when using testers and measuring instruments during a road test . . . . 2
1.4 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Safety precautions when working on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.6 Safety precautions when tow-starting or towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.5 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.6 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.7 Routing and attachment of lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Allocation gearbox - engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
32 - Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1 Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Assembly overview - torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Removing and installing torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Draining torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4 Removing and installing torque converter oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
37 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1 ATF circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.1 Assembly overview - ATF circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2 Removing and installing ATF cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3 Removing and installing ATF filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4 Removing and installing ATF lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2 ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.1 Checking ATF level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.2 Draining and filling ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.3 Purging ATF circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.1 Specified torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.2 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.3 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.1 Assembly overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.2 Assembly overview - selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.3 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6.4 Emergency release from position P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.5 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6.6 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6.7 Removing and installing gear selector cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Contents i
Amarok 2017 ➤
6.8 Checking and adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

6.9 Removing and installing cable support bracket for selector lever cable . . . . . . . . . . . . . . . . 65
6.10 Removing and installing gearbox selector lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
38 - Gears, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1 ATF system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.1 Assembly overview - sump/oil strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.2 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.3 Removing and installing hydraulic impulse oil storage with accumulator solenoid N485 . . 75
2 Oil seals in gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.1 Renewing oil seal in gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3 Mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.1 Removing and installing mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
ii Contents
Amarok 2017 ➤
00 – Technical data
1 Safety information
(VRL014569; Edition 08.2020)
⇒ p1.1 recautions when working on fuel supply system”, page
1
⇒ m1.2 easures when working on vehicles with a start/stop
system”, page 1
⇒ p1.3 recautions when using testers and measuring instru‐
ments during a road test”, page 2
⇒ p1.4 recautions when working on the cooling system”, page
2
⇒ p1.5 recautions when working on ignition system”, page 2
⇒ p1.6 recautions when tow-starting or towing”, page 2
1.1 Safety precautions when working on fuel supply system

Risk of injury from highly-pressurised fuel
The fuel system is pressurised. Risk of injury from fuel spray.
Before opening the fuel system:
– Wear protective goggles.
– Wear protective gloves.
– To release pressure, wrap a clean cloth around the connec‐
tion and carefully loosen the connection.
Danger of fire from escaping fuel

When the battery is connected and the driver door opens, the
door contact switch activates the fuel pump. Escaping fuel can
ignite and cause a fire.
– Disconnect voltage supply to fuel pump before opening the
fuel system.
1.2 Safety measures when working on vehicles with a start/stop system

Risk of injury due to unexpected motor start
If the vehicle's start/stop system is activated, the engine can
start unexpectedly. A message in the dash panel insert indi‐
cates whether the Start/Stop system is activated.
– Deactivate Start/Stop system by switching off the ignition.
1. Safety information 1
Amarok 2017 ➤
1.3 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury from unsecured test instruments and measuring
equipment
When the front passenger airbag is triggered in an accident, in‐
sufficiently secured testing and measuring instruments become
dangerous projectiles.
– Secure testing and measuring instruments on the rear seat.
or
– Have a second person operate the test instruments and
measuring equipment on the rear seat.
1.4 Safety precautions when working on the cooling system

Risk of scalding through hot coolant
On a warm engine, the cooling system is under high pressure.
Danger of scalding due to steam and hot coolant.
– Wear protective gloves.
– Wear protective goggles.
– Reduce excess pressure by covering the cap of the coolant
expansion tank with cloths and opening it carefully.
1.5 Safety precautions when working on ignition system

Risk of injury due to electric shock
The ignition system is under high voltage when the engine is
running. Touching the ignition system may result in an electric
shock.
– Do not touch or disconnect ignition cables when the engine
is running or at cranking speed.
Risk of damage to components

Connecting or disconnecting electric cables or washing the en‐
gine while it is running may damage components.
– Switch off the ignition before connecting or disconnecting
electric cables.
– Switch off the ignition before washing the engine.
1.6 Safety precautions when tow-starting or towing

Risk of irreparable damage to electric motor
Possibility of destroying electric motor when towing incorrectly.
2 Rep. gr.00 - Technical data

Amarok 2017 ➤
– Position selector lever in “N” when vehicle is being towed.

– 50 km/h must not be exceeded when being towed.
1. Safety information 3
Amarok 2017 ➤
2 Repair instructions
⇒ f2.1 or cleanliness”, page 4
⇒ i2.2 nformation”, page 4
⇒ r2.3 epair instructions”, page 4
⇒ c2.4 orrosion”, page 5
⇒ a2.5 nd seals”, page 5
⇒ a2.6 nd bolts”, page 6
⇒ a2.7 nd attachment of lines”, page 6
2.1 Rules for cleanliness

♦ Thoroughly clean all joints and surrounding areas before
dismantling.
♦ Use commercially available, lint-free cloths for cleaning.
♦ Seal open lines and connections immediately using clean
plugs or sealing caps from engine bung set -VAS 6122-.
♦ Place removed parts on a clean surface and cover them
over. Use plastic foils or lint-free cloths.
♦ If repair work cannot be performed immediately, cover new
parts which have been removed from their packing.
♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing.
♦ Protect disconnected electrical connectors from dirt and wa‐
ter, and reconnect them only when dry.
2.2 General information

♦ The engine control unit has a self-diagnosis capability. Be‐
fore carrying out repairs and for fault finding, first read event
memory.
♦ For trouble-free operation of electrical components, a volt‐
age of at least 11.5 volts is necessary.
♦ Do not use sealants containing silicone. Particles of silicone
drawn into the engine will not be burnt in the engine and
damage the Lambda probe.
♦ Vehicles are fitted with a crash fuel shut-off circuit. It reduces
the danger of a fire in a crash as the fuel pump is switched
off via the fuel pump relay.
♦ The system also improves the starting characteristics of the
engine. When the driver door is opened, the fuel pump is ac‐
tivated for 2 seconds to build up pressure in the fuel system.
2.3 General repair instructions

To ensure flawless and successful gearbox repairs, the greatest
care and cleanliness as well as the use of good and proper
tools are essential. Of course, the basic rules for safety also
apply during all repair work.
A number of general notes on the individual repair procedures,
which can otherwise be found in the relevant sections of the
workshop manual, are summarised here. They apply for this
particular workshop manual.

Amarok 2017 ➤
Notes on the gearbox

♦ If gearbox covers have been unbolted or gearbox has no
fluid, do not run engine or tow vehicle either.
♦ First thoroughly clean connecting points and surrounding
areas and then loosen bolts.
♦ When installing the gearbox, ensure that dowel sleeves be‐
tween the engine and gearbox are correctly located.
♦ Place removed parts on a clean surface and cover them to
prevent them from getting dirty. Use sheeting and paper for
this purpose. Use lint-free cloths only.
♦ If repair work cannot be performed immediately, carefully
cover or seal components.
♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing.
♦ Do not run engine or tow vehicle with pan removed or when
there is no ATF in gearbox.
♦ With gearbox removed, secure torque converter against fall‐
ing out.
♦ After installing, check ATF level ⇒ page 26 .
Sealant
♦ Thoroughly clean housing joint surfaces before applying
sealant.
♦ Evenly apply a thin coat of sealant ⇒ Electronic parts cata‐
logue (ETKA).
♦ Breather holes must remain free of sealant.
2.4 Contact corrosion

Contact corrosion can occur if non-approved fasteners are used
on the vehicle (bolts, nuts, washers etc.).
For this reason, only connecting elements with a special surface
coating have been fitted.
In addition, rubber, plastic and adhesives are made of non-con‐
ductive materials.
If there is any doubt about the suitability of parts, a general rule
is to use new parts ⇒ Electronic parts catalogue (ETKA).
2.5 Gaskets and seals

♦ Renew O-ring, seals and gaskets.
♦ When seals have been removed, check contact surface on
housings or shafts for burrs and damage and rectify as nec‐
essary.
♦ Before installing the seal, slightly moisten outer circumfer‐
ence of seal and sealing lip with ATF depending on installa‐
tion location.
2. Repair instructions 5
Amarok 2017 ➤
♦ Only use ATF for automatic transmission components. Other

types of lubrication cause faults to occur in the gearbox hy‐
draulics.
♦ Open side of oil seal faces oil.
♦ After installing, check ATF level ⇒ page 26 .
2.6 Nuts and bolts
♦ Specified torques given are for unoiled nuts, bolts and

screws.
♦ Always renew self-locking bolts and nuts.
♦ Always renew nuts and bolts that are tightened with turning
further angle.
2.7 Routing and attachment of lines

Risk of damage to lines
Lines may become damaged by moving or hot components.
– Route lines in their original positions.
– Make sure there is sufficient clearance between the lines
and moving as well as hot components.
– If necessary, renew cable ties, heat insulation sleeves, clips
and similar that had to be taken off for removal. Install them
in the same position.

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3 Technical data
⇒ 3.1 , page 7
⇒ g3.2 earbox - engine”, page 7
3.1 Capacities
Caution
Risk of malfunctions or failure of gearbox.

♦ Only the ATF ordered through the replacement part sys‐
tem can be used in automatic gearbox 0DR ⇒ Electronic
parts catalogue (ETKA).
Capacities Lubricant
Initial filling of gearbox by manu‐ approx. 10.0 l ATF
facturer
The ATF is obtainable as a spare part.

Container size: 1.0 l - Part No. ⇒ Electronic parts catalogue.
3.2 Allocation gearbox - engine

Gearbox 8-speed automatic gearbox 0DR
Gearbox Identifica‐ RMK RUP
tion code
Allocation Model Amarok 2017 ► Amarok 2017 ►
Engine 3.0 l - 150 kW turbo diesel 3.0 l - 165 kW turbo diesel
3.0 l - 165 kW turbo diesel
Ratio 1st gear 4.714 4.714
2nd gear 3.143 3.143
3rd gear 2.106 2.106
4th gear 1.667 1.667
5th gear 1.285 1.285
6th gear 1 1
7th gear 0.839 0.839
8th gear 0.667 0.667
Reverse 3.317 3.317
gear
3. Technical data 7
Amarok 2017 ➤
Gearbox 8-speed automatic gearbox 0DR

Gearbox Identi‐ SZG SZH SZZ
fica‐
tion
code
Allocation Model Amarok 2017 ► Amarok 2017 ► Amarok 2017 ►
En‐ 3.0 l - 150 kW turbo die‐ 3.0 l - 165 kW turbo die‐ 3.0 l - 150 kW turbo die‐
gine sel sel sel
3.0 l - 165 kW turbo die‐ 3.0 l - 190 kW turbo die‐
sel sel
Ratio 1st ge 4.714 4.714 4.714
ar
2nd g 3.143 3.143 3.143
ear
3rd ge 2.106 2.106 2.106
ar
4th ge 1.667 1.667 1.667
ar
5th ge 1.285 1.285 1.285
ar
6th ge 1 1 1
ar
7th 0.839 0.839 0.839
gear
8th 0.667 0.667 0.667
gear
Re‐ 3.317 3.317 3.317
verse
gear

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32 – Torque converter
1 Torque converter
⇒ o1.1 verview - torque converter”, page 9
⇒ a1.2 nd installing torque converter”, page 9
⇒ t1.3 orque converter”, page 11
⇒ a1.4 nd installing torque converter oil seal”, page 12
1.1 Assembly overview - torque converter
1 - Gearbox
❑ Removing and instal‐
ling ⇒ page 34
2 - Oil seal
ling ⇒ page 12
3 - O-ring
❑ Renew after removal
4 - Torque converter
ling ⇒ page 9
❑ Emptying ⇒ page 11
5 - Bolts
❑ Qty. 3
❑ 60 Nm
1.2 Removing and installing torque con‐

verter
Special tools and workshop equipment required
1. Torque converter 9
Amarok 2017 ➤
♦ Support bridge -30 - 211 A-
♦ Depth gauge
Removing
– Remove gearbox ⇒ page 34 .
– Use support bridge -30 - 211 A- to secure torque converter
in gearbox and prevent it falling out.
Note
Oil may escape when the torque converter is pulled out of the
gearbox.
– Remove torque converter in direction of arrow from gearbox.
– Renew O-ring and seal for torque converter.
10 Rep. gr.32 - Torque converter

Amarok 2017 ➤
Installing
Install in reverse order of removal, observing the following:

– Push torque converter in direction of arrow into gearbox as
far as stop.
– Check installation dimension.
The torque converter is properly installed when the gearbox can
be pushed against the engine flange without force.
– If this is not the case, fit the torque converter again.
Installation dimension
3 - Depth gauge
• If torque converter -2- is installed correctly, dimension -a-
between torque converter and gearbox housing -1- is ap‐
prox. 21 mm.
– Check and top up ATF level ⇒ page 26 .
1.3 Draining torque converter

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♦ Used oil collector and extractor -VAS 6622A-
– Extract ATF from torque converter -2- using used oil collec‐
tion and extraction unit -VAS 6622A- -1-.
1.4 Removing and installing torque con‐

verter oil seal
♦ Removal tool -VW 681-
♦ Thrust piece -T50067-
12 Rep. gr.32 - Torque converter

Amarok 2017 ➤
Removing
– Apply oil seal extractor lever directly behind sealing lip of oil
seal.
– Pry out seal with lever -VW681-.
Installing
– Apply ATF to circumference and sealing lips of oil seal.
• Installation position: open side of seal faces towards gear‐
box
– Using thrust piece -T50067-, drive in torque converter oil
seal to stop.
Amarok 2017 ➤
37 – Controls, housing
1 ATF circuit
⇒ o1.1 verview - ATF circuit”, page 14
⇒ a1.2 nd installing ATF cooler”, page 15
⇒ a1.3 nd installing ATF filter”, page 17
⇒ a1.4 nd installing ATF lines”, page 19
1.1 Assembly overview - ATF circuit
1 - ATF cooler
ling ⇒ page 15
2 - Bracket
3 - Return line
ling ⇒ page 19
4 - O-ring
❑ Qty. 8
❑ Moisten O-ring with
ATF before installing
5 - Thermostat
6 - Bracket
7 - Bolt
❑ 20 Nm
8 - Bolt
❑ 8 Nm
9 - Double line
ling ⇒ page 22
10 - Bolt
❑ 8 Nm
11 - Bolt
❑ Qty. 3
❑ 8 Nm
12 - Thermostat bracket
13 - Bolt
❑ Qty. 5
❑ 8 Nm +180°
14 - Supply line
❑ Removing and installing ⇒ page 19
15 - Bolt
❑ 2 Nm
14 Rep. gr.37 - Controls, housing

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1.2 Removing and installing ATF cooler

♦ Set of plugs for engine -VAS 6122-
♦ Drip tray for workshop hoist -VAS 6208-
♦ Torque wrench -V.A.G 1331-
Removing
Note
Seal open lines and connections using clean plugs from engine
bung set -VAS 6122-.
– Remove front bumper cover ⇒ General body repairs, exte‐

rior; Rep. gr. 63; Front bumper; Removing and installing
bumper cover.
– Unscrew bolts -arrows-.
1. ATF circuit 15
Amarok 2017 ➤
– Remove lock carrier support -1-.

– Place drip tray for workshop hoist -VAS 6208- under ATF
cooler.
– Unscrew bolt -arrow-.
– Pull off supply line -1- from ATF cooler -2-.

– Pull off return line -1- from ATF cooler -2-.

– Unscrew bolt -arrow- from ATF cooler -1-.

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– Unclip ATF cooler -2- from guide -arrow- on radiator for en‐
gine coolant -1-.
– Pull out ATF cooler -arrow- upwards from guide -1-.
Installing
– Moisten O-ring with ATF before assembly ⇒ Item 4 (page
14) .
Specified torques
♦ ⇒ o1.1 verview - ATF circuit”, page 14
♦ ⇒ General body repairs, exterior; Rep. gr. 63; Front bumper;
Assembly overview - bumper cover
1.3 Removing and installing ATF filter

1. ATF circuit 17
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Removing
– Place used oil collection and extraction unit -VAS 6622A-
under gearbox.
– Remove ATF sump ⇒ page 72 .
– Carefully pull ATF filter -arrow- downwards in
-direction of arrow- off mechatronic unit -1-.
Installing

– Fit new O-ring -2- on ATF filter -1-.
– Clean both solenoids -arrows-. The solenoids must be firmly
seated in guide.

Amarok 2017 ➤
– Fit ATF filter to mechatronic unit.
♦ The suction collar -1- of ATF filter must be inserted to stop

into opening -2- of mechatronic unit.
♦ Mounting -4- on the backside must engage in bolt -3- of
mechatronic unit.
– Install ATF sump ⇒ page 72 .
– Fill ATF ⇒ page 27 .
1.4 Removing and installing ATF lines

⇒ a1.4.1 nd installing ATF lines, ATF cooler/thermostat”, page
19
⇒ a1.4.2 nd installing ATF lines, thermostat/gearbox”, page 22
1.4.1 Removing and installing ATF lines,

ATF cooler/thermostat
1. ATF circuit 19
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Removing
Note
– Remove front bumper cover ⇒ General body repairs, exte‐

rior; Rep. gr. 63; Front bumper; Removing and installing
bumper cover.
– Remove left air duct ⇒ General body repairs, exterior; Rep.
gr. 50; Lock carrier; Assembly overview - lock carrier.
– Remove left charge air hose ⇒ Rep. gr. 21; Charge air sys‐
tem; Assembly overview - charge air system.

Amarok 2017 ➤
– Remove struts -1-.

– Place drip tray for workshop hoist -VAS 6208- underneath.
– Pull out ATF double line -1- from thermostat.

– Unscrew bolt -arrow- of return line -1-.
– Unscrew bolt -arrow- of supply line -1-.
1. ATF circuit 21
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– Unscrew bolts -arrows- from bracket.
– Remove ATF double line -1-.

Installing
Note
♦ Seals must be renewed.

♦ Moisten oil seals with ATF prior to installation.
Caution
If ATF cooler or ATF double line has been renewed, it must

then be filled ⇒ page 27 .

– Install front bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63; Front bumper; Removing and installing bumper
cover.
Specified torques
♦ ⇒ General body repairs, exterior; Rep. gr. 63; Front bumper;
Assembly overview - bumper cover
1.4.2 Removing and installing ATF lines,

thermostat/gearbox

Amarok 2017 ➤
Removing
Note
– If fitted, remove underbody guard ⇒ General body repairs,

exterior; Rep. gr. 66; Noise insulation.
– Remove bottom heat shield ⇒ page 34 .
– Place drip tray for workshop hoist -VAS 6208- underneath.
– Unscrew bolt -arrow- of ATF double line -1- from thermostat.
1. ATF circuit 23
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– Pull out ATF double line from thermostat.

– Unscrew bolt -1- of ATF double line -arrows-.
– Pull out ATF double line from gearbox.

– Unscrew bolts -arrows- of ATF double line -1- on gearbox
and engine.
– Carefully pull out ATF double line -1- forwards.

Installing
Note
♦ Seals must be renewed.

♦ Moisten oil seals with ATF prior to installation.

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Caution
If ATF cooler or ATF lines have been renewed, they must be

filled ⇒ page 27 .

– If removed beforehand, install underbody guard ⇒ General
body repairs, exterior; Rep. gr. 66; Noise insulation.
Specified torques
1. ATF circuit 25
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2 ATF
⇒ A2.1 TF level”, page 26
⇒ a2.2 nd filling ATF”, page 27
⇒ A2.3 TF circuit”, page 32
2.1 Checking ATF level

♦ Vehicle diagnostic tester

Conditions for testing
• Gearbox must not be in emergency running mode.
• Vehicle must be standing absolutely level.
• Gearbox is set to position “P”.
• Extraction hose/extraction hoses of a switched-on exhaust
gas extraction system is/are connected.
• Heating and air conditioning system are switched off.
• ⇒ Vehicle diagnostic tester is connected.
• At the beginning of the test, the maximum ATF temperature
must be between 35 and 45°C. If this temperature is excee‐
ded, the gearbox first must cool off.
Observe test prerequisites:
• Parking brake applied
• Test temperature: 35 – 45°C max.
under gearbox.
Note
Disregard bolt -1-.
– At idling speed, unscrew ATF inspection plug -2-.

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– Renew ATF inspection plug with seal -arrow-.
If ATF drips out of inspection hole:

ATF need not be topped up.
– Tighten new ATF inspection plug to specified torque.
If no ATF drips out of inspection hole:
– ATF must be topped up ⇒ page 30 .
Specified torques
Component Specified torque
ATF inspection plug 35 Nm
2.2 Draining and filling ATF

♦ Adapter for oil filling -VAS 6262 A-
♦ Adapter swivel hose -VAS 6262/5-
2. ATF 27
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♦ Adapter -VAS 6262/6-, if necessary
♦ Engine and gearbox jack -VAS 6931-
♦ Vehicle diagnostic tester
Note
Drained ATF oil must not be reused.
Capacity ⇒ 3.1 , page 7 .
Caution
Make sure the vehicle is in a level position when checking,

topping up or filling ATF. An improper ATF level hinders the
function of the gearbox.

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Note
If the oil temperature is above 45°C, allow the gearbox to cool

down.
Conditions
• Engine switched off.
• Gearbox must not be in emergency running mode.
• Vehicle must be standing absolutely level.
• Gearbox is set to position “P”.
• Extraction hose/extraction hoses of a switched-on exhaust
gas extraction system is/are connected.
• Heating and air conditioning system are switched off.
• ⇒ Vehicle diagnostic tester is connected.
• At the beginning of work, the maximum ATF temperature
must be between 35 and 45°C. If this temperature is excee‐
ded, the gearbox first must cool off.
WARNING
Risk of eye injury.

♦ Wear safety goggles.
Draining ATF
– Position engine and gearbox jack -VAS 6931- under transfer
box.
– Unclip wiring routed on gearbox cross member -2- and vehi‐
cle frame -1- -arrows-.
Note
To provide a better overview, the gearbox cross member and

vehicle frame are shown as a bird’s-eye view.
– Unscrew bolts -arrows- of gearbox cross member -1- and

bolts -arrows A- of gearbox mounting -2-.
2. ATF 29
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– Remove gearbox cross member -1- with gearbox mounting

-2-.
– Slightly raise gearbox with engine and gearbox jack -VAS
6931-.

under gearbox.
Note
Disregard bolt -2-.
– Remove ATF drain plug -1- from sump.

– Drain ATF.
Adding ATF
• Tighten ATF drain plug -1- in sump.
– Install gearbox cross member with gearbox mounting.
– Raise and tie up oil container holder with adapter for oil
filling -VAS 6262 A- as high up on the vehicle as possible.
Note
Disregard bolt -1-.
– Unscrew ATF inspection plug -2-.

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– Insert adapter for ATF oil filling -VAS 6262/5- into ATF in‐
spection and filler hole -arrow-.
– Pour in ATF through adapter until ATF runs out of inspection

and filler hole.
– Start engine and immediately fill more ATF until it flows out
of overflow edge -arrow-.
– Screw in plug for ATF inspection/filler hole hand-tight.

– Run engine at idling speed.
– With brake pressed, shift through all selector lever positions
at idling speed and make sure each position is engaged for
at least 10 seconds.
– Switch selector lever to “P” position.
2. ATF 31
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– Keep constant engine speed of 2000 rpm for 30 seconds to

allow torque converter to be filled.
– Allow gearbox to cool down to test temperature of between
35 and 45°C.
– Check ATF level, and add ATF if necessary.
– Tighten ATF inspection plug.
– Carry out a road test to bring ATF temperature up to at least
90°C in order for ATF radiator thermostat to open complete‐
ly.
– Allow gearbox to cool down to test temperature of between
35 and 45°C.
– Check ATF level, and add ATF if necessary.
– Tighten ATF inspection plug.
Specified torques
ATF oil drain plug 12 Nm
ATF inspection plug 35 Nm
2.3 Purging ATF circuit
WARNING
Wear protective goggles.
– If ATF is dirty or if an exchange gearbox is to be installed,

blow out ATF cooler and ATF lines with compressed air
(10 bar max.).
– Thoroughly clean area around unions for gearbox to ATF
line, ATF line to thermostat and ATF line to ATF cooler.
– Remove bolt -1- and pull ATF lines out of thermostat -2-.
– Unbolt ATF lines from and to ATF cooler at thermostat -2-. In

the process, hold against thermostat.
– Remove and drain ATF cooler ⇒ page 15 .
– Remove ATF lines -arrows- from gearbox.

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– Push a hose onto one end of the ATF line between gearbox
and thermostat and secure with a hose clip. Hang other end
of hose in a suitable container.
– Blow out ATF line with compressed air (10 bar max.).
– Push hose onto other ATF line and repeat procedure.
– Moisten O-ring with ATF.
– Install ATF pipes ⇒ page 19 .
– Install ATF cooler ⇒ page 15 .
Specified torques
2. ATF 33
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3 Removing and installing gearbox

⇒ t3.1 orques for gearbox”, page 34
⇒ g3.2 earbox”, page 34
⇒ g3.3 earbox”, page 43
3.1 Specified torques for gearbox

Specified torques for gearbox

-Item 1-, -item 2-, -item 3-: M 12 × 80 80 Nm
-Item 4-, -item 5-, -item 6-, -item 7-: 45 Nm
M 10 × 75
-Item 8-, -item 9-: M 12 × 80 (starter 80 Nm
bolts)
-Item 10-, -item 11-: M 12 × 80 80 Nm
-Arrows- Dowel sleeves
for centring en‐
gine/gearbox in cyl‐
inder block
Tightening torque for heat shields on gearbox
– Push bottom heat shield in direction of -arrow- into clip -3-.

Top heat shield -1- to gearbox 8 Nm
Bottom heat shield -2- to gear‐ 8 Nm
box
3.2 Removing gearbox


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♦ Support stand -VAS 281 001-
♦ Socket AF 16 -T50069-
3. Removing and installing gearbox 35

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♦ Support bridge -30-211A-
Procedure
– Remove front left wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66; Wheel housing liners; Removing
and installing front wheel housing liner.
– Support engine in installation position ⇒ Rep. gr. 10; Remov‐
ing and installing engine; Assembly mountings; Supporting
engine in installation position.
Note
The front and rear propshafts are not removed completely.
– Remove front and rear propshafts from transfer box ⇒ Rep.

gr. 39; Propshaft; Removing and installing propshaft.
– Secure rear propshaft -1- to underside of vehicle using wire
-arrow-.
– Release locking element of electrical connector -1- by turn‐

ing anti-clockwise in direction of -arrow-.

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– Unclip wiring harness -2- from gearbox and gearbox cross

member -arrows- and lay to side.
– Pull securing clip -arrow- in -direction of arrow- off selector
lever cable -1- and out of guide.
Note
The selector lever cable is not detached from the cable support
bracket until the gearbox is removed.

– Detach catalytic converter bracket -1- from gearbox.

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– Tie SCR hoses -1- aside with a cable tie -2-.

– Unscrew bolt -2-.
– Remove gearbox cover -1-.

– Using a cranked ring spanner -arrow-, turn crankshaft -1-
in direction of engine rotation until torque converter bolts
become accessible.

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Note
♦ Only turn crankshaft in direction of engine rotation -arrow-.

♦ Counterhold crankshaft with ring spanner when loosening
torque converter.
– Unscrew bolts 1 to 6 using socket AF 16 -T50069-.
Note
The quantity of bolts may vary depending on the equipment

level.

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– Pull ATF double line -arrows- out of gearbox.

– Open clamp -1-.
– Detach catalytic converter -2- from turbocharger, move in

direction of -arrow-, and secure it with a cable tie.
– Unclip gearbox breather pipe -1- from bracket -2-.
– Guide out gearbox breather pipe -1- downwards.

– Unscrew bolt -arrow- of refrigerant line -1- from gearbox.

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– Support gearbox on transfer box using support stand -VAS

281 001-.
Note


– Unscrew bolts -arrows- of gearbox cross member -1-.

– Unscrew bolts -arrows A- of gearbox mounting -2-.
– Remove gearbox cross member -1- together with gearbox

mounting -2-.
Note
To remove, use engine and gearbox jack -VAS 6931-.

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– Support gearbox on a foam underlay -B- with engine and

gearbox jack -VAS 6931- -A-.
– Secure gearbox with tensioning straps -C-.

– Remove support stand -VAS 281 001- and lower gearbox
slightly.
– Unscrew top engine/gearbox bolts -1- and -11-.
– Raise gearbox back to installation position.

– Unscrew remaining engine/gearbox bolts. Use socket AF 16
-T50069- if necessary.
Note
A second mechanic is required to assist in removal of the gear‐

box.
– Press gearbox off engine (dowel sleeves) and pull out to

rear.
Caution
When pulling out and lowering the gearbox, observe the fol‐
lowing components:
♦ Gearbox breather pipe
♦ Refrigerant line on gearbox
♦ SCR lines on particulate filter
♦ Exhaust gas temperature sender on particulate filter
– Carefully lower gearbox -1- using engine and gearbox jack.

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Note
Tilt the gearbox slightly if necessary via the spindles on the

engine and gearbox jack.
– Use support bridge -30 - 211 A- to secure torque converter

in gearbox and prevent it falling out.
– If a new gearbox is to be installed, remove the cable support

bracket -1-.
3.3 Installing gearbox

Procedure
– If ATF is dirty or if an exchange gearbox is to be installed,
clean ATF cooler and ATF lines ⇒ page 32 .

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– Check installation dimension -a- ⇒ page 11 .

– Support gearbox on a foam underlay -B- with engine and
gearbox jack -VAS 6931- -A-.
– Secure gearbox with tensioning straps -C-.

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– Insert engine/gearbox bolts -1- to -11- and tighten. Do not

screw in bolt -3- yet.
Note
To tighten engine/gearbox bolts, use socket AF 16 -T50069- if

necessary.
– Support gearbox on transfer box using support stand -VAS

281 001-.
– Remove engine and gearbox jack -VAS 6931-.
– Bring gearbox cross member -1- with gearbox mounting -2-
into position of vehicle frame and gearbox.
– Screw in bolts for gearbox cross member -arrows- and bolts

of gearbox mounting -arrows A- and tighten.
Using socket AF 16 -T50069-, tighten torque converter to drive
plate -arrow- as follows:
– Screw in first bolt -1- and tighten to 10 Nm before loosening

again. Then screw in hand-tight.
– Turn crankshaft on vibration damper 180° in direction of en‐
gine rotation.
– Screw in bolt -4-, and tighten it ⇒ Item 5 (page 9) .
– Turn crankshaft 60° in direction of engine rotation as re‐
quired, screw in bolts -5- and -6- and tighten.
– Turn crankshaft 60° further in direction of engine rotation,
tighten bolt -1-.
– Turn crankshaft 60° further in direction of engine rotation as
required, screw in bolts -2- and -3- and tighten.
– Tighten engine/gearbox bolt -2-.

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– Fit gearbox cover -1-.

– Remove cable tie -2-.
– Tighten bolt of steering line -arrow-.

– Secure bracket for catalytic converter -1- using bolts
-arrows-.
– Install selector lever cable -arrow-.

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– Check and adjust selector lever cable ⇒ page 63 .

– Secure ATF double line -arrows- on gearbox connection us‐
ing bolt -1-.
– Secure ATF double line -1- on gearbox and engine using

bolts -arrows-.
– Install bottom heat shield ⇒ page 34 .

– Secure refrigerant line -1- on gearbox with bolt -arrow-.
– Engage electrical connector -1- by turning clockwise against

direction of -arrow-.

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– Clip in wiring harness -2- on gearbox and gearbox cross

member -arrows-.
– Clip in gearbox breather pipe -1- on bracket -2-.
– Secure catalytic converter -2- on turbocharger with clamp

-1-.
– Install front and rear propshaft ⇒ Rep. gr. 39; Propshaft;

Removing and installing propshaft.
– Check ATF level ⇒ page 26 .
– If removed beforehand, install underbody guard ⇒ General
body repairs, exterior; Rep. gr. 66; Noise insulation.
– Install front left wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66; Wheel housing liner; Removing and
installing front wheel housing liner.
Specified torques
♦ ⇒ t3.1 orques for gearbox”, page 34
♦ ⇒ o4.1 verview - assembly mountings”, page 50

Amarok 2017 ➤
♦ ⇒ o6.1 verview - selector mechanism”, page 54

♦ ⇒ Rep. gr. 21; Turbocharger; Assembly overview - turbo‐
charger
♦ ⇒ Rep. gr. 26; Emission control system; Assembly overview
- emission control system
Steering line to 8 Nm
catalytic convert‐
er
Refrigerant line to 8 Nm
gearbox

Amarok 2017 ➤
4 Assembly mountings
⇒ o4.1 verview - assembly mountings”, page 50
4.1 Assembly overview - assembly mount‐

ings
Bolts for securing gearbox mounting on gearbox
– Using bolts -1-, bolt gearbox mounting -A- to gearbox.

– Always renew bolts -1-.
Bolts -1- 50 Nm +90°
Bolts for securing gearbox mounting on gearbox carrier
– Using bolts -1-, bolt gearbox mounting -A- to gearbox carrier.

– Always renew bolts -1-.
Bolts -1- 30 Nm +90°
Tightening torque for gearbox cross member -1-

Amarok 2017 ➤

Bolts -2- 50 Nm +45°
Bolts -3- 50 Nm +90°
Bolts -4- 20 Nm +90°
4. Assembly mountings 51
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5 Transporting gearbox
♦ Workshop hoist -VAS 6100-
♦ Lifting tackle -3033-
♦ hooks -10-222A/20-
WARNING
The gearbox should only be transported with the torque con‐

verter and auxiliary drive mounted as otherwise the centre of
gravity will be affected.
– Secure lifting tackle -3033- -2- on workshop hoist -VAS

6100- -1-.

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– Engage hooks -10-222A/20- -3- in lifting eyes of manual

gearbox.
WARNING
Hooks on the lifting tackle must be secured with locking pins.
Input shaft side:

Second »position« from outside on lifting tackle -3033-
-arrow B-.
Output shaft side:
Inner »position« of lifting tackle -3033- -arrow A-.
5. Transporting gearbox 53
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6 Selector mechanism
⇒ o6.1 verview - selector mechanism”, page 54
⇒ o6.2 verview - selector lever handle”, page 55
⇒ s6.3 elector mechanism”, page 56
⇒ r6.4 elease from position P”, page 57
⇒ a6.5 nd installing selector mechanism”, page 58
⇒ a6.6 nd installing selector lever handle”, page 60
⇒ a6.7 nd installing gear selector cable”, page 63
⇒ a6.8 nd adjusting selector lever cable”, page 63
⇒ a6.9 nd installing cable support bracket for selector lever
cable”, page 65
⇒ a6.10 nd installing gearbox selector lever”, page 68
6.1 Assembly overview - selector mechanism

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1 - Nuts
❑ For selector mecha‐
nism
❑ 8 Nm
2 - Selector lever handle
❑ With selector cover ⇒
page 55
ling ⇒ page 60
3 - Frame for selector cover
4 - Centre tunnel
5 - Securing clip for selector
lever cable
❑ On cable support
bracket
6 - Adjuster screw
❑ For selector lever cable
❑ 12 Nm
7 - Bolts
❑ For cable support
bracket
❑ 8 Nm
8 - Cable support bracket
ling ⇒ page 65
9 - Securing clip for selector
lever cable
❑ On selector mechanism
10 - Selector mechanism with
gear selector cable
❑ Emergency release from position »P« ⇒ page 57
❑ Check shift mechanism ⇒ page 56
❑ Check and adjust selector lever cable ⇒ page 63
11 - Selector housing
12 - Seal
13 - Centre console
6.2 Assembly overview - selector lever handle
6. Selector mechanism 55
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1 - Handle with gear lever

gaiter
❑ Cannot be separated
from selector cover ⇒
Item 3 (page 56)
ling ⇒ page 60
2 - Clip
❑ For attaching handle to
selector lever
3 - Selector cover
❑ Is removed together
with handle
6.3 Checking selector mechanism
WARNING
Before working on vehicle with engine running, move selec‐

tor lever into position “P” and apply handbrake.
• The starter must not operate in the selector lever positions

“S”, “D”, “R” and “Tiptronic gate”.
• When the vehicle is moving at speeds above 5 km/h and
the selector lever is shifted to position “N”, the solenoid for
selector lever lock must not engage and block selector lever.
Selector lever can be shifted into a driving range.
• When the vehicle is moving at speeds below 2 km/h (almost
stationary) and the selector lever is shifted to position “N”,
the solenoid for selector lever lock should only engage after
about 1 second. Selector lever cannot be shifted out of “N”
position until brake pedal is depressed.
Selector lever in “P” position, ignition switched on:
– Do not operate brake pedal.

Amarok 2017 ➤
• Selector lever is locked and cannot be shifted out of “P” po‐

sition with the lock button pressed on selector lever handle.
Solenoid for selector lever lock -N110- blocks selector lever.
– Press brake pedal and keep it pressed down.
• Solenoid for selector lever lock -N110- releases selector lev‐
er. It is possible to shift into a driving gear. With lock button
pressed on selector lever handle slowly shift selector lever
through positions “R, N, D, S” starting at position “P”. Check
whether selector lever position display -Y6- in dash panel
insert corresponds to selector lever position.
Selector lever in “N” position, ignition switched on:
– Do not operate brake pedal.
• After a short waiting time: Selector lever is locked and can‐
not be shifted out of “N” position despite lock button being
pressed on selector lever handle. Solenoid for selector lever
lock -N110- blocks selector lever.
– Operate brake pedal.
• Solenoid for selector lever lock -N110- releases selector lev‐
er. “D” position can be engaged.
Selector lever in “D” position, ignition switched on:
– Shift selector lever into “Tiptronic gate”.
• Illuminated “D” symbol in selector lever position display -
Y26- must go out and “+” and “–” symbols must light up.
Selector lever position indicator
Simultaneous illumination of all selector lever position display
segments indicates gearbox emergency running mode.
– Check and adjust selector lever cable.
6.4 Emergency release from position P

♦ Removal wedge -3409-
Note
♦ Selector lever cannot be moved out of “P” position when

battery is disconnected or flat.
♦ Operating emergency release causes selector lever lock sol‐
enoid -N110- to release lock when it is de-energised.
– Unclip selector cover -1- from frame using removal wedge

-3409- -arrows-.
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– Only raise selector cover far enough for manual release

mechanism to become accessible.
– Press emergency release lever downwards in direction of
- arrow- using your finger or a screwdriver while at the same
time pushing button of handle and shifting selector lever out
of position “P”.
– Install selector cover.
6.5 Removing and installing selector

mechanism
Removing
Before removing, mark positions of all parts relative to each
other. Reinstall in same position or imbalance will be excessive.
Damage to bearing and rumbling noises may result.
– Remove front and rear propshaft from transfer box, move to
one side and tie ⇒ Rep. gr. 39; Propshaft; Removing and
installing propshaft.
Note
The front and rear propshafts are not removed completely.
– Remove transfer box ⇒ Rep. gr. 39; Transfer box; Removing

and installing transfer box.
– Pull securing clip -arrow- out of guide in direction of -arrow-
and off selector lever cable -1-.

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– Pull out adjuster screw -arrow- from ball head of selector

lever cable.
– Remove selector lever handle ⇒ page 60 .

– Disconnect all connectors.
Note
The number of electrical connectors depends on the vehicle's

equipment.
– Unclip frame for selector cover -1- -arrows-.
– Unscrew nuts -arrows-.
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– Remove selector mechanism -1- downwards.

– When removing selector mechanism, guide selector lever
cable out of cable support bracket.
Installing

– Tighten nuts -arrows- of selector mechanism -1- ⇒ Item 1
(page 55) .
– Install selector lever handle ⇒ page 60 .
– Install transfer box ⇒ Rep. gr. 39; Transfer box; Removing
Specified torques
6.6 Removing and installing selector lever

handle

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♦ Hose clip pliers -V.A.G 1275 A-
♦ Removal wedge -3409-
♦ Assembly tool -T10534-
Removing
– Shift selector lever to position “D”.

– Unclip selector cover -1- from frame using removal wedge
-3409- -arrows-.
– Separate electrical connector.
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– Pull gear lever gaiter upwards off gear knob.

– Remove clamp -arrow-.
– Pull handle off selector lever, without pressing button.
Note
Handle is removed together with selector cover.
Installing
• Selector lever is in position “D”.
Note
♦ The button might have been pressed into the handle. Do not
install a handle with the button pressed in.
♦ New handle is supplied with installation guard. Only remove
securing clip immediately prior to installation.
If the button was pressed in by mistake, the installation position

can be restored. To do this, push installation guard or assembly
tool -T10534- fully in whilst button is pressed, release button
and pull installation guard or assembly tool -T10534- out again.
Button engages in installation position.

Amarok 2017 ➤
– Push handle with new clamp fully onto selector lever until it
can be felt to engage.
– Press button in selector lever handle.
Note
If not installed correctly, button remains inserted in handle after

being pressed. Handle must be re-installed.
– Attach new clamp -arrow- using hose clip pliers -V.A.G

1275-.
6.7 Removing and installing gear selector

cable
The selector lever cable is not available as an individual re‐
placement part ⇒ Electronic parts catalogue (ETKA).
For removal and installation instructions, refer to ⇒ page 58 .
6.8 Checking and adjusting selector lever

cable
♦ Release lever -80-200-
Amarok 2017 ➤
Check

– Press selector lever cable on ball head -arrow- off gearbox
using removal lever -80-200-.
– Move selector lever from “P” to “D”.
• Selector lever cable must move easily and smoothly.
– Move selector shaft lever on gearbox to position “P”. Move
detent lever to rearmost position towards “rear axle” in direc‐
tion of -arrow-.
• It must be possible to push selector lever cable onto selector
shaft lever. Adjust selector lever cable if necessary.
– Carefully press selector lever cable onto selector shaft lever.
Do not bend selector shaft lever or selector can no longer be
precisely adjusted.
Adjusting
– Remove selector lever cable from selector shaft lever.
– Move selector shaft lever on gearbox to position “P”. Move
detent lever to rearmost position towards “rear axle”.
– Loosen bolt -arrow-, press selector lever cable onto selector
shaft lever.
Note
Do not pull selector lever backwards or forwards when tighten‐

ing the bolt, otherwise setting could be falsified.

Amarok 2017 ➤
– Tighten adjuster screw for selector lever cable.

Specified torques
6.9 Removing and installing cable support

bracket for selector lever cable
♦ Release lever -80 - 200-
Removing
Before removing, mark positions of all parts relative to each
other. Reinstall in the same position otherwise imbalance will be
Amarok 2017 ➤
excessive, the mountings could be damaged causing rumbling

noises.
– Unscrew bolts -arrows- for rear propshaft -1-.

– Remove propshaft from flange -2-.
– Tie up propshaft -1- at a suitable location using wire -arrow-.

box.
– Unclip wiring routed along gearbox cross member -2-
-arrows-.


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– Remove gearbox cross member with gearbox mounting.
Note
Remove gearbox cross member with gearbox mounting with aid

of second mechanic.
– Lower gearbox carefully with engine and gearbox jack -VAS

6931- until cable support bracket bolts can be accessed
more easily.
– Pull securing clip -arrow- in -direction of arrow- off selector
lever cable -1- and out of guide.
– Pull out adjuster screw -arrow- from ball head of selector

lever cable.
– Unscrew bolts -arrows- from cable support bracket -1-.
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– Guide cable support bracket out of selector lever cable.

Installing
Specified torques
6.10 Removing and installing gearbox se‐

lector lever
Removing
– Remove sump ⇒ page 72 .
– Remove mechatronic unit ⇒ page 80 .
– Detach selector mechanism from gearbox ⇒ page 58 .
Note
Remove any residue of old locking pin -arrow- from gearbox.
– Drive out locking pin -arrow- with a drift.
– Pull gearbox selector lever and seal out of gearbox.

Amarok 2017 ➤
Installing
Note
♦ Remove any residues of old locking pin from gearbox.

♦ Renew seal and drive it in as far as stop using a suitable
thrust piece.
♦ Drive in new locking pin so that it is flush.
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38 – Gears, control
1 ATF system
⇒ o1.1 verview - sump/oil strainer”, page 70
⇒ a1.2 nd installing sump”, page 72
⇒ a1.3 nd installing hydraulic impulse oil storage with accumula‐
tor solenoidN485”, page 75
1.1 Assembly overview - sump/oil strainer
70 Rep. gr.38 - Gears, control

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1 - Mechatronic unit
ling ⇒ page 80
2 - Bolt
❑ Note tightening se‐
quence ⇒ page 84
❑ 8 Nm
3 - Seal
4 - Hydraulic impulse accu‐
mulator with accumulator sol‐
enoid -N485-
ling ⇒ page 75
5 - Bolt
❑ 8 Nm
6 - Seal
7 - ATF filter
ling ⇒ page 17
8 - Solenoids
❑ Ensure solenoids are
properly seated on ATF
filter with their entire
surface
❑ Clean prior to installa‐
tion
❑ Not available as a re‐
placement part anymore. Cannot be separated from ⇒ Item 7 (page 71)
9 - Seal
10 - Bolt
❑ 12 Nm
11 - Drain plug
❑ 12 Nm
12 - ATF pan
13 - Bolt
❑ Note tightening sequence ⇒ page 84
❑ 8 Nm
14 - Seal
❑ ATF pump intake
15 - Connecting piece with seal
1. ATF system 71
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❑ Oil supply for ATF pump
1.2 Removing and installing sump

Removing
Note
Support gearbox using engine and gearbox jack -VAS 6931-

ensuring that sump can still be removed in the following work
procedure.

Amarok 2017 ➤

box.
Note


– Remove gearbox cross member -1- with gearbox mounting

-2-.
– Slightly raise gearbox with engine and gearbox jack -VAS
6931-.
– Unscrew ATF drain plug and drain ATF ⇒ page 27 .
under gearbox.
– Unscrew bolts for sump -1- to -13-.
1. ATF system 73
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– Remove sump -1- downwards in -direction of arrow-.
Installing
Note
♦ Renew ATF sump bolts and gasket.

♦ In case of high mileage vehicles it is recommended to renew
the ATF filter once the ATF sump has been removed ⇒ page
17 .
♦ Otherwise, the ATF filter must only be renewed when dam‐
aged.
– Clean both solenoids -arrows-. The solenoids must be firmly

seated in guide.
– Thoroughly clean sealing surface. Ensure that residues from

old gasket are removed completely.

Amarok 2017 ➤
– Ensure proper seating of ATF filter on mechatronic unit. Oth‐

erwise the ATF sump cannot be fitted properly.
♦ The suction collar -1- of ATF filter must be inserted to stop

into opening -2- of mechatronic unit.
♦ Mounting -4- on the backside must engage in bolt -3- of
mechatronic unit.
– Tighten bolts in the specified sequence.
– Install gearbox cross member with gearbox mounting.

Specified torques
♦ ⇒ o1.1 verview - sump/oil strainer”, page 70
1.3 Removing and installing hydraulic im‐

pulse oil storage with accumulator sol‐
enoid -N485-
Note
The hydraulic impulse oil storage is not installed in all gearbox‐

es.
1. ATF system 75
Amarok 2017 ➤
Removing
• Gearbox is installed.
Caution
Risk of damage to gearbox.

♦ The engine must not be started when there is no ATF in
the gearbox and the mechatronic unit is removed.
– Shift selector lever to position “P”.
– Switch off ignition and remove ignition key.

– Remove ATF filter ⇒ page 17 .
– Carefully pull off electrical connector -arrow- on hydraulic
pulse accumulator -1-.
Caution
Risk of damaging gearbox control unit (mechatronic unit)

through electrostatic discharge.
♦ Before handling electrical connector, the person han‐
dling it must “electrostatically discharge” himself/herself.
To do so, briefly touch e.g. an earth connection, a radia‐
tor in the workshop or a lifting platform with the hand.
♦ Do not touch contacts in the gearbox connector with
hands.
– Unscrew bolts -arrows- from hydraulic pulse accumulator

-1-.

Amarok 2017 ➤
– Remove hydraulic impulse oil storage.

Installing
Note
♦ Renew O-ring and bolts for hydraulic pulse accumulator.

♦ Ensure that connector is properly engaged and secured.
– Insert hydraulic impulse oil storage with new O-ring.

– Observe tightening sequence of bolts ⇒ page 85 .
– Connect connector to hydraulic impulse oil storage.
– Install ATF filter ⇒ page 17 .
Specified torques
♦ ⇒ a1.2 nd installing sump”, page 72
1. ATF system 77
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2 Oil seals in gearbox

⇒ o2.1 il seal in gearbox”, page 78
2.1 Renewing oil seal in gearbox

Renewing output shaft seal
♦ Puller -T10055-
♦ Thrust piece -T50068-
Removing
– Remove transfer box ⇒ Rep. gr. 39; Transfer box; Removing

– To pull out seal, screw sheet metal screw of about 4 mm
diameter into seal -arrow-.
♦ Screw in self-tapping screw so its is clamped between seal
and metal cover.
♦ Do not screw in sheet metal screw too far to avoid damaging
bearing behind it.

Amarok 2017 ➤
– Pull out seal using puller -T10055-.

Installing

– Especially coat sealing lips of new seal with ATF.
– Drive in oil seal to stop using thrust piece -T50068- -1-.
Note
Do not cant oil seal in the process.
– Install transfer box ⇒ Rep. gr. 39; Transfer box; Removing

– Finally, check ATF level and top up ⇒ page 26 .
2. Oil seals in gearbox 79

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3 Mechatronic unit
⇒ a3.1 nd installing mechatronic unit”, page 80
3.1 Removing and installing mechatronic

unit
♦ Guide bolt -T40199-
Removing
WARNING
Do not run engine or tow vehicle with pan removed or when

there is no ATF in gearbox.
• Gearbox is installed.
– Shift selector lever to position “P”.
– Switch off ignition and remove ignition key.
– Remove ATF filter ⇒ page 17 .
Gearbox with hydraulic pulse accumulator
– Remove hydraulic pulse accumulator ⇒ page 75 .

Amarok 2017 ➤
Continued for all vehicles
Caution
Risk of damaging gearbox control unit (mechatronic unit)

through electrostatic discharge.
♦ Before handling electrical connector, the person han‐
dling it must “electrostatically discharge” himself/herself.
To do so, briefly touch e.g. an earth connection, a radia‐
tor in the workshop or a lifting platform with the hand.
♦ Do not touch contacts in the gearbox connector with
hands.
– Unlock connector -arrow- by turning it anti-clockwise in

-direction of arrow-.
– Unscrew bolt and pull catch -1- of connector downwards in

-direction of arrow-.
– Pull connector housing -arrow- in -direction of arrow- out of

gearbox -1-.
3. Mechatronic unit 81
Amarok 2017 ➤
Caution
Risk of damaging mechatronic unit.

♦ Only the bolts with Torx T40 heads may be loosened.
♦ Only the marked bolts may be loosened.
♦ Loosening other bolts may affect the operation of the
mechatronic unit, or the mechatronic unit could come
apart.
Note
♦ Bolt -16- has already been removed during removal of con‐

nector housing.
♦ Do not yet remove bolt -1-.
– Unscrew bolts in sequence -18 to 2-. Pull out gearbox output

speed sender -G195- after bolt -17- has been loosened, in
order to prevent the sender from being damaged.
– Screw in the 4 guide pins -T40199- hand-tight into holes

-2, 5, 13, 14-.
Caution
Risk of damaging senders on backside of mechatronic unit.

♦ Only lay down mechatronic unit with bolt head side fac‐
ing downwards.
– Remove mechatronic unit downwards.

Amarok 2017 ➤
1 - Electronic module with sensors

2 - Electronic gearbox control
3 - Hydraulic valve body
4 - Solenoid valves
5 - Gearbox connector
Installing
♦ Moisten seals with ATF before fitting. Do not use any other
lubricants.
♦ Always renew a valve body which is fouled or defective.
♦ Only use lint-free cloths.
♦ Renew connecting piece with seals ⇒ Item 15 (page 71) .
♦ Renew seal for oil passage between gearbox and mecha‐
tronic unit ⇒ Item 14 (page 71) .
Note
♦ Renew bolts for mechatronic unit.

♦ The guide pins -T40199- prevent the mechatronic unit from
tilting during installation. This ensures that the ATF lines on
the backside of the mechatronic unit are not being damaged.
♦ Thus, the aid of a 2nd mechanic is recommended when
installing the mechatronic unit with gearbox installed.
– The gearbox selector lever must be seated in the groove of

the slide block and of the selector slide -arrows-.
Amarok 2017 ➤
– Screw in new bolts -1, 3, 4- by hand until bolt heads make

contact with mechatronic unit.
– Unscrew the 4 guide pins -T40199-.
– Install new connector housing (prior to installing bolt -16-).
Note retaining tabs -arrows-. The housing can only be fitted
in one specific installation position. Then, lock securing clip.
Note
Do not tighten bolt -16- until after the securing clip has been
properly locked.
– Tighten new bolts for mechatronic unit in sequence given.

Tightening sequence for mechatronic unit without hydraulic
pulse accumulator

Amarok 2017 ➤
Tightening sequence for mechatronic unit with hydraulic im‐

pulse oil storage
– Install ATF filter ⇒ page 17 .

– Adapt mechatronic unit using ⇒ Vehicle diagnostic tester.
Specified torques
♦ ⇒ a1.2 nd installing sump”, page 72

VW Amarok 8 Speed Automatic Gearbox 0dr Eng

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Service

Service Department. Technical Information

6.8 Checking and adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

1.1 Safety precautions when working on fuel supply system

Danger of fire from escaping fuel

1.2 Safety measures when working on vehicles with a start/stop system

1.4 Safety precautions when working on the cooling system

1.5 Safety precautions when working on ignition system

Risk of damage to components

1.6 Safety precautions when tow-starting or towing

2 Rep. gr.00 - Technical data

– Position selector lever in “N” when vehicle is being towed.

2.1 Rules for cleanliness

2.2 General information

2.3 General repair instructions

4 Rep. gr.00 - Technical data

Notes on the gearbox

2.4 Contact corrosion

2.5 Gaskets and seals

♦ Only use ATF for automatic transmission components. Other

2.6 Nuts and bolts

♦ Specified torques given are for unoiled nuts, bolts and

2.7 Routing and attachment of lines

6 Rep. gr.00 - Technical data

Risk of malfunctions or failure of gearbox.

The ATF is obtainable as a spare part.

3.2 Allocation gearbox - engine

Gearbox 8-speed automatic gearbox 0DR

8 Rep. gr.00 - Technical data

1.1 Assembly overview - torque converter

1.2 Removing and installing torque con‐

♦ Support bridge -30 - 211 A-

– Remove torque converter in direction of arrow from gearbox.

– Renew O-ring and seal for torque converter.

10 Rep. gr.32 - Torque converter

Install in reverse order of removal, observing the following:

1.3 Draining torque converter

♦ Used oil collector and extractor -VAS 6622A-

1.4 Removing and installing torque con‐

♦ Thrust piece -T50067-

12 Rep. gr.32 - Torque converter

1.1 Assembly overview - ATF circuit

14 Rep. gr.37 - Controls, housing

1.2 Removing and installing ATF cooler

♦ Drip tray for workshop hoist -VAS 6208-

♦ Torque wrench -V.A.G 1331-

– Remove front bumper cover ⇒ General body repairs, exte‐

– Remove lock carrier support -1-.

– Pull off supply line -1- from ATF cooler -2-.

– Pull off return line -1- from ATF cooler -2-.

16 Rep. gr.37 - Controls, housing

– Pull out ATF cooler -arrow- upwards from guide -1-.

1.3 Removing and installing ATF filter

♦ Used oil collector and extractor -VAS 6622A-

Install in reverse order of removal, observing the following:

18 Rep. gr.37 - Controls, housing

– Fit ATF filter to mechatronic unit.

♦ The suction collar -1- of ATF filter must be inserted to stop

1.4 Removing and installing ATF lines

1.4.1 Removing and installing ATF lines,

♦ Set of plugs for engine -VAS 6122-

♦ Drip tray for workshop hoist -VAS 6208-

♦ Torque wrench -V.A.G 1331-