D4B8026D002-6-Speed Manual Gearbox 0C6

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Amarok 2011 ➤
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Amarok 2017 ➤
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6-speed manual gearbox 0C6
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
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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 © 2019 Volkswagen AG, Wolfsburg D4B8026D002

Amarok 2011 ➤ , Amarok 2017 ➤
6-speed manual gearbox 0C6 - Edition 06.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 1
1.2 Safety precautions when using testers and measuring instruments during a road test . . . . 1
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2 Allocation gearbox - engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1 Clutch operation . . . . . . . . . . . . . . . . . . . . e. n. A. G. ..V.o.lk.sw. a. g.e.n .A.G. . . . . . . . . . . . . . . . . . . . . . . . 10
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1.1 Assembly overview - clutch mechanism Vol . . . . . . . . . . . . . . . . . . . . .ot.g.u . . . . . . . . . . . . . . . . .
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1.2 Assembly overview - clutch release ris
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1.3 Removing and installing over-centre aut
h spring . . . . . . . . . . . . . . . . . . . . . . . e.or.a. . . . . . . . . . . 12
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1.4 Removing and installing mounting ss bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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1.5 Removing and installing clutch master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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1.6 Bleeding clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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1.7 Removing and installing clutch pedal switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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2 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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2.1 Assembly overview - clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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2.2 Removing and installing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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1.1 Installation position - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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1.2 Assembly overview - gear knob and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

1.3 Assembly overview - Gear lever and selector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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1.4 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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1.5 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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1.6 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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1.7 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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1.8 Dismantling and assembling selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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2 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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2.1 Specified torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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2.2 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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2.3 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
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3 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
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3.1 Assembly overview - assembly mountings, version A . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

3.2 Assembly overview - assembly mountings, version B . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.3 Removing and installing gearbox mountings, version B . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.1 Schematic overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.2 Assembly overview - clutch housing and input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.3 Assembly overview - gearbox housing, layshaft, output shaft and selector unit . . . . . . . . 53
5.4 Assembly overview - selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.5 Assembly overview - selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Contents i
5.6 Removing and installing propshaft flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

5.7 Removing and installing adapter shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.8 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6 Gearbox housing, clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
6.1 Assembly overview - gearbox housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
6.2 Assembly overview - clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
6.3 Repairing gearbox housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
6.4 Repairing clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
7 Gear oil . . . . . . . . . . . . . . . . . . . . . . . a. g.e.n .A.G.. V. o.lk.s.w.ag. e.n.A.G.d.o. . . . . . . . . . . . . . . . . . . . . . . . 87
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7.1 Checking gear oil level . . . . . . .y .Vo. lk. s. . . . . . . . . . . . . . . . . . . . n.o.t g.u. . . . . . . . . . . . . . . . . . . 87
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7.2 Draining and filling gear oil or.is.e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ra. n.te. . . . . . . . . . . . . . . .
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35 - Gears, shafts . . . . . . . . s. . .
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1 Input and output shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
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1.1 Assembly overview - input shaft and output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
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1.2 Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
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1.3 Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
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1.4 Renewing output shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
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2 Layshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
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2.1 Assembly overview - layshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2.2 Dismantling and assembling layshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
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3 Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
3.1 Assembly overview - reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
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3.2 Removing and installing reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
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ii Contents
6-speed
. Volkswage
manual gearbox 0C6 - Edition 06.2019
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00 – Technical data
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1 Safety information
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(VRL013193; Edition 06.2019)
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⇒ “1.1 Safety measures when working on vehicles with a start/
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stop system”, page 1
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⇒ “1.2 Safety precautions when using testers and measuring in‐
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struments during a road test”, page 1
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1.1 Safety measures when working on ve‐
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hicles with a start/stop system
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Observe the following when working on vehicles with a start/stop

system:
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WARNING
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Injury hazard as a result of automatic engine start in vehicles

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♦ In vehicles with the start/stop system activated (identifia‐
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♦ When working on the vehicle, always make sure that the
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switch the ignition on again if necessary).
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1.2 Safety precautions when using testers

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

test and measuring equipment.
Danger as a result of activation of front passenger airbag in
event of an accident.
• Operation of test and measuring equipment while driving
results in distraction.
• Greater injury hazard as a result of unsecured test and
measuring equipment.
♦ Always strap in place test and measuring equipment on
rear seat and have a 2nd person sitting on the rear seat
to operate them.
1. Safety information 1
2 Identification
⇒ “2.1 Gearbox identification”, page 2
2.1 Gearbox identification

Location on manual gearbox -arrow-
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Code letters -arrow- and date of manual gearbox manufacture
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Example MQV 23 07 09
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Identifica‐ Day Month Year (2009)
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Additional data depend on manufacture.

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The manual gearbox code is also included on the vehicle data

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2 Rep. gr.00 - Technical data

3 Repair instructions
⇒ “3.1 General repair instructions”, page 3
⇒ “3.2 Gaskets and seals”, page 5
⇒ “3.3 Nuts and bolts”, page 5
3.1 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 dur‐
ing 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 par‐
ticular workshop manual.
Special tool
♦ For a complete list of special tools used in this workshop man‐
ual, see ⇒ Workshop equipment and special tools .
Gearbox
♦ During installation, ensure that the dowel sleeves between the . Volkswage
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♦ When installing mounting brackets or waxed components,
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clean the contact surfaces. Contact surfaces tho must be free of tee
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♦ When exchanging manual gearbox, check oil level

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⇒ page 87 .
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♦ When exchanging manual gearbox, always install a new re‐
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lease bearing with hydraulic actuation ⇒ page 12 .
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The release bearing with hydraulic actuation is supplied with the
manual gearbox.
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3. Repair instructions 3
Locking devices
♦ Renew retaining rings.
♦ Do not overstretch retaining rings.
♦ Retaining rings must locate properly in grooves.
♦ Renew spring pins. Installation position: slot must be in line
with direction of force.
Mountings
♦ Lubricate all gearbox bearings with gear oil before installing.
♦ Install needle bearing and roller bearing with lettered side
(thicker metal) facing towards fitting drift.
Synchro-rings
♦ Do not interchange them. When reusing synchro-rings, always
fit to the same synchromeshed gear.
♦ Check for wear and renew if necessary.
♦ Moisten synchromesh mechanism with gear oil before instal‐
ling.
Gears and synchro-hubs
♦ Before pressing on gear wheel for 3rd gear and constant mesh
gear, clean them and heat them with inductive heater - VAS
6414- to max. 150 C.
♦ Before installing synchro hub, clean and heat with the induc‐
tive heater - VAS 6414- to maximum 100°C.
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♦ Observe installation position
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Synchromeshed gears ir se
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check synchromeshed gears for slight axial ac
clearance of at least 0.10 mm, or for freedom of movement.
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♦ Ensure that the pressure plate does not cant: loosen and tight‐
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en bolts alternately and diagonally and in several gradual

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♦ If the clutch has burnt out, thoroughly clean the clutch housing
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as well as the friction surface of flywheel with a cloth to reduce

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the smell of burnt linings.

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3.2 Gaskets and seals

♦ Before installing oil seals, half-fill space between sealing lips
with sealing grease -arrow- ⇒ Electronic parts catalogue (ET‐
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♦ The open side of the oilyseals
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♦ Lightly oil the oil
s a seals before installing; this prevents the rings
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♦ Following installation, check gear oil level ⇒ page 87 .
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Sealant
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♦ Thoroughly clean housing joint surfaces before applying seal‐
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♦ Evenly apply a thin coat of sealant ⇒ Electronic parts cata‐
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logue (ETKA) .
♦ Breather holes must remain free of sealant.
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3.3 Nuts and bolts
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♦ Loosen and tighten bolts and securing nuts for covers and
housings in diagonal sequence.
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♦ Do not cant especially delicate parts, such as clutch pressure
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plates. Loosen and tighten bolts and nuts in stages in a diag‐

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♦ Specified torques given are for unoiled nuts, bolts and screws.
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♦ Always renew self-locking bolts and nuts.

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♦ Ensure with threaded connections that contact surfaces as
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well as nuts and bolts are rewaxed only after assembly, if nec‐
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♦ Use a thread chaser (thread tap) to clear residual locking fluid
from all threaded holes into which self-locking bolts are to be
screwed. Otherwise there is a danger of bolts shearing when
subsequently being removed.
♦ Check pitch of thread, to ensure correct thread chaser is used
to clean threads and to ensure the threads are not damaged.
3. Repair instructions 5
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Capacity of manual 1.5 l
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Allocate gear oil using ⇒ Electronic parts catalogue (ETKA) .
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– Draining and filling gear oil ⇒ page 88
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Identification code MQU NCE NCR NFG
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Allocation Model Amarok 2011 ► Amarok 2011 ► Amarok 2011 ► Amarok 2011 ►
AG.
Amarok 2017 ►
Engine 2.0 l - 90 kW turbo 2.0 l - 90 kW turbo 2.0 l - 90 kW turbo 2.0 l - 90 kW turbo
diesel diesel diesel diesel
2.0 l - 120 kW tur‐ 2.0 l - 103 kW turbo 2.0 l - 118 kW FSI 2.0 l - 118 kW FSI
bo diesel diesel 2.0 l - 120 kW turbo 2.0 l - 120 kW turbo
2.0 l - 132 kW turbo diesel diesel
diesel 2.0 l - 132 kW turbo
diesel
Gear ratios 1st gear 43 : 12 = 3.583 43 : 12 = 3.583 43 : 12 = 3.583 43 : 12 = 3.583
2nd gear 34 : 18 = 1.889 34 : 18 = 1.889 34 : 18 = 1.889 34 : 18 = 1.889
3rd gear 39 : 35 = 1.114 39 : 35 = 1.114 39 : 35 = 1.114 39 : 35 = 1.114
4th gear 1 : 1 = 1.000 1 : 1 = 1.000 1 : 1 = 1.000 1 : 1 = 1.000
5th gear 31 : 55 = 0.564 31 : 55 = 0.564 31 : 55 = 0.564 31 : 55 = 0.564
6th gear 26 : 55 = 0.473 26 : 55 = 0.473 26 : 55 = 0.473 26 : 55 = 0.473
Reverse 39 : 12 = 3.250 39 : 12 = 3.250 39 : 12 = 3.250 39 : 12 = 3.250
gear
Glean following data from ⇒ Electronic parts catalogue (ETKA) :
♦ Specification for gear oil
♦ Clutch allocation
♦ Allocation of rear final drive according to engine code

Identification code NNW NPS NYS NYT
Amarok 2017 ►


Identification code NNW NPS NYS NYT
Engine 2.0 l - 90 kW turbo 2.0 l - 118 kW FSI 2.0 l - 90 kW turbo 2.0 l - 118 kW FSI
diesel diesel
2.0 l - 103 kW turbo 2.0 l - 120 kW turbo
diesel diesel
2.0 l - 118 kW FSI 2.0 l - 132 kW turbo
2.0 l - 132 kW turbo diesel
diesel
Gear ratios 1st gear 43 : 12 = 3.583 43 : 12 = 3.583 43 : 12 = 3.583 43 : 12 = 3.583
2nd gear 34 : 18 = 1.889 34 : 18 = 1.889 34 : 18 = 1.889 34 : 18 = 1.889
3rd gear 39 : 35 = 1.114 39 : 35 = 1.114 39 : 35 = 1.114 39 : 35 = 1.114
4th gear 1 : 1 = 1.000 1 : 1 = 1.000 1 : 1 = 1.000 1 : 1 = 1.000
5th gear 31A:G55
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26 : 55 = 0.473 26 : 55gu = 0.473 26 : 55 = 0.473 26 : 55 = 0.473
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Reverse 39 : 12 = 3.250 39 : 12 = 3.250
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39 : 12 = 3.250 39 : 12 = 3.250
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Identification code PCY PCZ PEK
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Allocation Model Amarok 2011 ► Amarok 2011 ► Amarok 2011 ►

l purpos
Engine 2.0 l - 90 kW turbo diesel 2.0 l - 118 kW FSI 2.0 l - 118 kW FSI
nform
ercia

m
Gear ratios 1st gear 43 : 12 = 3.583 43 : 12 = 3.583 43 : 12 = 3.583

at
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2nd gear 34 : 18 = 1.889 34 : 18 = 1.889 34 : 18 = 1.889

in t
or
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3rd gear 39 : 35 = 1.114 39 : 35 = 1.114 39 : 35 = 1.114

at
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4th gear 1 : 1 = 1.000 1 : 1 = 1.000 1 : 1 = 1.000

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5th gear 31 : 55 = 0.564 31 : 55 = 0.564 31 : 55 = 0.564
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Reverse 39 : 12 = 3.250 39 : 12 = 3.250 39 : 12 = 3.250
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4.2.2 Allocation gearbox - engine, all-wheel drive

Manual gearbox 6-speed manual gearbox 0C6, all-wheel drive
Identification code MQV NCD NCQ NFF
4. Technical data 7

Identification code MQV NCD NCQ AG. Volkswagen
NFF
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Engine 2.0 l - 90 kW turbo 2.0 l - 90 kW turbo y2.0 Vol l - 90 kW turbo 2.0 l - 90s nkW
ot g turbo
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diesel diesel ed
b
diesel diesel arant
ris
2.0 l - 120 kW turbo 2.0 l - 103 kWutturbo
ho 2.0 l - 120 kW turbo 2.0 l - 120 kW turbo ee
or
diesel diesel
ss
a diesel diesel ac
2.0 l - 132 kW turbo 2.0 l - 132 kW turbo
ce
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nl
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diesel diesel
du
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Gear ratios 1st gea 43 : 12 = 3.583 43 : 12 = 3.583 43 : 12 = 3.583 43 : 12 = 3.583
erm
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2nd ge 34 : 18 = 1.889 34 : 18 = 1.889 34 : 18 = 1.889 34 : 18 = 1.889
, is n
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3rd gea 39 : 35 = 1.114 39 : 35 = 1.114
es, in part or in w
39 : 35 = 1.114 39 : 35 = 1.114
t to the co
r
4th gea 1 : 1 = 1.000 1 : 1 = 1.000 1 : 1 = 1.000 1 : 1 = 1.000
r
rrectness of i
5th gea 31 : 55 = 0.564 31 : 55 = 0.564 31 : 55 = 0.564 31 : 55 = 0.564
l purpos
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6th gea 26 : 55 = 0.473 26 : 55 = 0.473 26 : 55 = 0.473 26 : 55 = 0.473
r
nf
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Re‐ 39 : 12 = 3.250 39 : 12 = 3.250 39 : 12 = 3.250 39 : 12 = 3.250
m
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verse
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♦ Allocation of transfer box according to manual gearbox iden‐ co Vo
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tification code
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♦ Allocation of front and rear final drives according to engine

identification code

Identification code NNV NYR PCX
Allocation Model Amarok 2011 ► Amarok 2011 ► Amarok 2011 ►
Amarok 2017►
Engine 2.0 l - 90 kW turbo diesel 2.0 l - 90 kW turbo diesel 2.0 l - 90 kW turbo diesel
2.0 l - 103 kW turbo diesel 2.0 l - 120 kW turbo diesel 2.0 l - 120 kW turbo diesel
2.0 l - 132 kW turbo diesel 2.0 l - 132 kW turbo diesel 2.0 l - 132 kW turbo diesel
Gear ratios 1st gear 43 : 12 = 3.583 43 : 12 = 3.583 43 : 12 = 3.583
2nd gear 34 : 18 = 1.889 34 : 18 = 1.889 34 : 18 = 1.889
3rd gear 39 : 35 = 1.114 39 : 35 = 1.114 39 : 35 = 1.114
4th gear 1 : 1 = 1.000 1 : 1 = 1.000 1 : 1 = 1.000
5th gear 31 : 55 = 0.564 31 : 55 = 0.564 31 : 55 = 0.564
6th gear 26 : 55 = 0.473 26 : 55 = 0.473 26 : 55 = 0.473
Reverse 39 : 12 = 3.250 39 : 12 = 3.250 39 : 12 = 3.250
gear
♦ Allocation of transfer box according to manual gearbox iden‐
tification code

♦ Allocation of front and rear final drives according to engine

identification code
AG. Volkswagen AG d
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4. Technical data 9
30 – Clutch
AG. Volkswagen AG d
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⇒ “1.1 Assembly overview - clutch
oris mechanism”, page 10
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⇒ “1.2 Assembly overviews - clutch release mechanism”,
s a c
page 12
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⇒ “1.3 Removing and installing over-centre spring”, page 12

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⇒ “1.4 Removing and installing mounting bracket”, page 13
ility
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⇒ “1.5 Removing and installing clutch master cylinder”,
h re
page 14
hole
spec
es, in part or in w
⇒ “1.6 Bleeding clutch mechanism”, page 16
t to the co
⇒ “1.7 Removing and installing clutch pedal switch”, page 17
1.1 Assembly overview - clutch mechanism
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1 - Brake fluid reservoir
nform
ercia
2 - Supply hose
m
a
3 - Nut
com
tion in
❑ For securing clutch
r
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master cylinder
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❑ Renew after removal cum

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❑ Self-locking
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❑ 9 Nm
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4 - Mounting bracket
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❑ The mounting bracket
AG.
and clutch pedal are a

unit and cannot be sep‐
arated
❑ Removing and installing
⇒ page 13
5 - Over-centre spring
⇒ page 12
6 - Nut
❑ For securing mounting
bracket
❑ Renew after removal
❑ 25 Nm
7 - Clutch pedal switch for stop/
start system - F71-
❑ For vehicles with stop/
start system
❑ To ensure that it is suffi‐
ciently secured, clutch
pedal switch for stop/
start system - F71- may
only be installed once
❑ Removing and installing ⇒ page 18
8 - Clutch pedal switch - F36-
❑ To ensure that it is sufficiently secured, clutch pedal switch - F36- may only be installed once
10 Rep. gr.30 - Clutch

9 - Bearing mounting
❑ Insert with polycarbamide grease ⇒ Electronic parts catalogue (ETKA)
10 - Bolts
❑ For securing clutch master cylinder
❑ Qty. 2
11 - Retaining clip
Volkswagen AG
12 - Clutch master cylinder agen
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❑ Removing and installing ⇒ page e14
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13 - Seal au
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❑ Replace only if damaged s
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❑ Pull onto line connection
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❑ Insert with brake fluid
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14 - Seal
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❑ Replace only if damaged
h re
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spec
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t to the co
15 - Bracket
❑ Secured to bulkhead
rrectness of i
16 - Pipe/hose line
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17 - Gearbox
nform
ercia
18 - Bleeder
m
at
❑ To clutch slave cylinder ⇒ page 12
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19 - Retaining clip
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1. Clutch operation 11
1.2 Assembly overview - clutch release mechanism
1 - Gearbox
❑ Installing and removing
⇒ page 38
2 - Protective cap
3 - Bleeder
❑ With bleeder valve
❑ Breather must engage
fully in clutch slave cyl‐
inder when installing.
4 - O-ring
❑ Ensure correct seating
5 - Release bearing with clutch
slave cylinder
❑ Are one unit and can on‐
ly be renewed together AG. Volkswagen AG d
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❑ Do not wash out bear‐ Volksw
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❑ Renew noisy bearings ut
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with clutch slave cylin‐ ss a c
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❑ Must always be re‐
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newed when exchang‐
rm
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ing gearbox
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❑ Fix loosely with bolts
, is n
h re
and engage/lock with
hole
spec
breather, only then pro‐
es, in part or in w
ceed to final tightening
t to the co
6 - Bolt
rrectness of i
❑ 9.5 Nm
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nform
ercia
1.3 Removing and installing over-centre

m
spring
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tion in
r
Removing
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– Remove mounting bracket ⇒ page 13 .

r
rp
cum
fo
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– Depress clutch pedal.

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– Press over-centre spring -A- in -direction of arrow- out of clutch

mounting -B-.
Installing
Install in reverse order of removal, observing the following:
– Install mounting bracket with clutch pedal ⇒ page 13 .
Specified torques AG. Volkswagen AG d
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♦ ⇒ “1.1 Assembly overview - clutch bmechanism”,
yV
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1.4 Removing and installing mounting
itte
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bracket
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Special tools and workshop equipment required
h re
hole
spec
♦ Torque wrench - V.A.G 1331-
es, in part or in w
t to the co
rrectness of i
l purpos
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or
♦ Hose clamps to 25 mm - 3094-

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Removing
– If fitted, remove clutch pedal switch for stop/start system - F71-
⇒ page 18 .
– Remove clutch pedal switch - F36- ⇒ page 17 .
– Pull off securing clip -1-.

– Drive out mounting bracket -2-.
– Unscrew nuts -3-.
– Pull out bolts -4-.
– Unscrew nuts -arrows-.

– Remove mounting bracket with clutch pedal.
Note
♦ The clutch master cylinder remains installed.

♦ The mounting bracket and clutch pedal are a unit and cannot
be separated.
AG. Volkswagen AG d
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Install in reverse order riseof
d
removal, observing the following: nte
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Bearing pin can sonly
s a be inserted from left. ra
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Insert bearing pin with polycarbamide grease ⇒ Electronic parts

un
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catalogue (ETKA) .
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– If removed, install clutch pedal switch for stop/start system -

ility
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F71- ⇒ page 18 .
wit
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– Install clutch pedal switch - F36- ⇒ page 17 .

ole,
spec
urposes, in part or in wh
Specified torques
t to the co
♦ ⇒ “1.1 Assembly overview - clutch mechanism”, page 10

rrectne
1.5 Removing and installing clutch master

cylinder
ss o
cial p

inform
mer
♦ Torque wrench - V.A.G 1331 -

atio
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or
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Removing
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery .

Caution
During the following work, ensure that no brake fluid lands on

longitudinal member or gearbox. If this does happen, clean the
affected areas thoroughly.
– Clamp off supply hose -1- using hose clamps up to 25 mm -

3094- .
– Pull off supply hose -1- on brake fluid reservoir and seal open‐
ing to prevent brake fluid leaking out.
– Pull securing clip in -direction of arrow-.
– Pull out pipe/hose assembly -2-.
– Remove clutch pedal switch - F36- ⇒ page 17 .
– If fitted, remove clutch pedal switch for stop/start system - F71-
⇒ page 18 .
– Unscrew nuts -arrows-.

– Remove mounting bracket with clutch master cylinder.
AG. Volkswagen AG d
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– Pull off securing clip -2-.

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– Drive out mounting bracket -1-.

h re
ole,
spec
– Unscrew nuts -4- and pull out bolts.

t to the co
– Remove clutch master cylinder -3-.

Installing
rrectne

Bearing pin can only be inserted from left.
ss o
cial p
– Insert bearing pin with polycarbamide grease ⇒ Electronic

inform
parts catalogue (ETKA) .

mer
atio
m
– Install clutch pedal switch - F36- ⇒ page 17 .

o
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or
– Bleed clutch mechanism ⇒ page 16 .

thi
te
sd
iva
– Install battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Re‐

pr
cum
r
fo
moving and installing battery .

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ng
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Specified torques C py
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♦ ⇒ “1.1 Assembly overview - clutch mechanism”, page 10
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1.6 Bleeding clutch mechanism
Note
♦ Bleeding may only be carried out using the brake filling and
bleeding equipment.
♦ The connection of the bleeder must be free of deposits con‐
taining mineral oil.

♦ Brake filling and bleeding unit - VAS 5234-
Procedure AG. Volkswagen AG d

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– Screw adapter -1- onto brake fluid reservoird b-2-.
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– Connect brake filling and bleeding equipment
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Comply with operating instructions for brake filling and bleeding

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equipment - VAS 5234- .

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spec
Bleeder valve is located on left side of gearbox.

t to the co
– Pull cap off bleeder valve of clutch slave cylinder -arrow-.

rrectne
– Push breather hose of collector bottle onto bleeder valve of

clutch slave cylinder.
ss
– Pressurise system to 2 bar.

o
cial p
f inform
– Open bleeder valve by about 1/4 turn.

mer
atio
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– Rapidly operate pedal cluster from stop to stop 15 to 20 times.

o
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or
– Close bleeder valve.

thi
te
sd
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– Once bleeding procedure is complete and a pressure of 2 bar

p
cum
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fo
has been released, operate clutch pedal ten more times by

en
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foot.
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1.7 Removing and installing clutch pedal
ce
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switch
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⇒ “1.7.1 Removing and installing clutch pedal switch F36 ”, page
wit
17
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⇒ “1.7.2 Removing and installing clutch pedal switch for stop/start
spec
system F71 ”, page 18
es, in part or in w
t to the co
1.7.1 Removing and installing clutch pedal
switch - F36-
rrectness of i
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Note
nf
ercia
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To ensure that it is sufficiently secured, clutch pedal switch - F36-
rm
m
may only be installed once.
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Removing
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– Separate electrical connector -1- from clutch pedal switch -

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F36- -2-.
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– Release clutch pedal switch - F36- -2- by turning it 45° anti-

clockwise. Then pull out of mounting bracket.
Installing
– Move clutch pedal to rest position (not actuated)
-arrow showing direction of motion-.
Note
Clutch master cylinder -1- must be installed completely

⇒ page 14 .
– Coat switch plunger from clutch pedal switch - F36- -2- with
polycarbamide grease ⇒ Electronic parts catalogue (ETKA) .
AG. Volkswagen AG d
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– Insert clutchtho
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is
- F36- -2- into the access hole e oof
mounting aubracket -1-. ra
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– Push clutch pedal switch - F36- over resistance of clutch pedal

nl
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in direction of -arrow A- and secure in place with a 45° turn to
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the right in direction of -arrow B-.
erm
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– Attach electrical connector -1- to clutch pedal switch - F36-
l purpos
-2-.
nform
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ion
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1.7.2 Removing and installing clutch pedal
Prote AG.
switch for stop/start system - F71-
Note
To ensure that it is sufficiently secured, clutch pedal switch for

stop/start system - F71- may only be installed once.
Removing
– Separate electrical connector from clutch pedal switch for
stop/start system - F71- -2-.
– Release clutch pedal switch for stop/start system - F71- by
turning 45° in anti-clockwise direction and pull out of assembly
opening of mounting bracket.
Installing

AG. Volkswagen AG d
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agen 6-speed manual oes gearbox 0C6
not - Edition 06.2019
Vo gu
d by ara
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– Move clutch pedal to rest position
horis (not actuated) nte
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-arrow showing direction of amotion-.
ut ra
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– Coat switch plunger from clutch pedal switch for stop/start
ce
le
un
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system - F71- -2- with polycarbamide grease ⇒ Electronic
an
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The clutch master cylinder must be fully installed in the mounting
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– Insert clutch pedal switch for stop/start system - F71- -2- into
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assembly opening of mounting bracket -1-.

– Push clutch pedal switch for stop/start system - F71- against
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clutch pedal pressure in direction of -arrow A- and secure by

turning 45° in clockwise direction -arrow B-.
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– Fit electrical connector on clutch pedal switch for stop/start
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2 Clutch
⇒ “2.1 Assembly overview - clutch”, page 20
⇒ “2.2 Removing and installing clutch”, page 22
2.1 Assembly overview - clutch
Note
♦ Renew clutch plates and pressure plates with damaged or

loose rivet connections.
♦ Renew pressure plate and clutch plate together only.
♦ Select clutch plate and pressure plate according to engine
code and ⇒ Electronic parts catalogue (ETKA) .
♦ Clean splines of drive shaft and, if the clutch plate has been
n AG. Volkswagen A
used, clean the splines of the hub. Remove corrosion and
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ply a very thin coat of clutch plate spline greasedto by splines ⇒
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Electronic parts catalogue (ETKA) . Then, move ris the clutch
e
tee
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plate back and forth on the drive shaft untilau the hub moves
t or
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easily on the shaft. Remove excess grease. ss
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♦ It is essential to insert dowel sleeves provided for centring en‐
an
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gine/gearbox in cylinder block.
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1 - Two-part flywheel
❑ Ensure that centring
pins fit tightly
❑ Contact surface for
clutch lining must be
free of grooves, oil and
grease
⇒ Rep. gr. 13 ; Cylinder
block (gearbox end);
Assembly overview - fly‐
wheel .
2 - Clutch plate
❑ Renew only together olkswage es n
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with clutch plate.
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⇒ page 22
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❑ Check ends of dia‐
phragm spring
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⇒ page 22
❑ Checking spring con‐
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nections and riveted
or
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⇒ page 22
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Installation position of clutch plate:

• Lettering “Getriebeseite” and protruding spring cage must face
gearbox.
2. Clutch 21
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Amarok 2011 ➤au,t Amarok 2017 ➤ ra
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Check ends of diaphragm spring
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Checking spring connections and riveted connections

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– Check spring connections -arrows A- for damage and riveted
on in
connections -arrows B- for secure seating.
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Checking position of adjustment mechanism is necessary only for

new pressure plates from “LuK”
♦ Both edges -A- of the adjuster ring must be located between
the two notches -arrows B-.
♦ If the adjuster ring takes up a different position in new pressure
plates, the pressure plate and clutch plate are not allowed to
be installed.
♦ The adjuster ring may take up a position outside the notches
in used clutches.
2.2 Removing and installing clutch


♦ Counter-hold tool - 3067-
♦ Centring mandrel - 3434-
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♦ Grease ⇒ Electronic parts catalogue (ETKA)

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2. Clutch 23
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6-speed manual gearbox 0C6 - Edition
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– Remove gearbox ⇒ page 38 .
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Illustration shows position of counterhold - 3067- for installation.
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Change over counterhold - 3067- for removal.
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– Loosen bolts in small steps and diagonally.
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– Remove pressure plate and clutch plate.

Installing
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♦ Select clutch plate and pressure plate according to engine
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♦ Pressure plates are protected against corrosion and greased.
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Clean contact surface only. Otherwise, the service life of the
clutch will be considerably reduced.
♦ Contact surface for clutch lining on dual-mass flywheel must
be free of grooves, oil and grease.
♦ Clean splines of drive shaft and, if the clutch plate has been
used, clean the splines of the hub. Remove corrosion and ap‐
ply a very thin coat of clutch plate spline grease to splines ⇒
Electronic parts catalogue (ETKA) . Then, move the clutch
plate back and forth on the drive shaft until the hub moves
easily on the shaft. Remove excess grease.
♦ Check whether dowel sleeves for aligning engine and gearbox
are fitted in cylinder block and install if necessary.
♦ If dowel sleeves are not fitted, difficulties shifting gears, clutch
problems and possible noises from the gearbox (rattling of
gears which are not engaged) could occur.
Used pressure plate

– Check ends of diaphragm spring ⇒ page 22 .
– Check spring connections and riveted connections
⇒ page 22 .
New pressure plate
– Check position of adjusting mechanism of new pressure plate
⇒ page 22 .

Continuation for all

– Interchange counterhold - 3067- .
– Centre clutch plate with centring mandrel - 3434- .
Note
Lettering “Getriebeseite” and protruding spring cage must face

gearbox.
– Push pressure plate onto centring pins.
Note
Pressure plate contact surface and clutch plate lining must make
full contact with flywheel or with pressure plate.
– Tighten all bolts evenly by hand until bolt heads contact pres‐
sure plate.
– Tighten bolts in small steps diagonally in order not to damage
centring holes of pressure plate
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mass flywheel. olkswag es n
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– Install gearbox
ris
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Specified
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♦ ⇒ “2.1 Assembly overview - clutch”, page 20

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♦ ⇒ “2.1 Specified torques for gearbox”, page 38

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2. Clutch 25
34 – Controls, housing
1 Selector mechanism
⇒ “1.1 Installation position - selector mechanism”, page 26
⇒ “1.2 Assembly overview - gear knob and cover”, page 28
⇒ “1.3 Assembly overview - Gear lever and selector housing”,
page 28
⇒ “1.4 Removing and installing selector mechanism”, page 29
⇒ “1.5 Adjusting selector mechanism”, page 31
⇒ “1.6 Checking selector mechanism”, page 34
⇒ “1.7 Removing and installing selector lever handle”,
page 35
⇒ “1.8 Dismantling and assembling selector mechanism”,
page 36
1.1 Installation position - selector mechanism

Arrow -A- = gear selection movement
Arrow -B- = gate selection movement
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26 Rep. gr.34 - Controls, housing

A - Gear selector rod for gear

selection movement
B - Gate selector rod and
movement
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1. Selector mechanism 27
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2 - Gear knob
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❑ Selector lever knob and
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❑ Remove and install to‐
spec
gether with gaiter
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⇒ page 35
3 - Clip
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4 - Selector lever
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1.3 Assembly overview - Gear lever and se‐

lector housing
Note
Gate selector rod, selector rod and selector housing are one unit
and can only be renewed together.

1 - Selector housing
❑ with selector lever
⇒ page 29
❑ Checking function of se‐
lector mechanism
⇒ page 34
❑ Adjusting selector
mechanism
⇒ page 31
2 - Hexagon nut
❑ 8 Nm
3 - Gearbox selector lever
❑ With damper weight
⇒ page 36
❑ Removing ⇒ page 36
4 - Relay lever
⇒ page 36
5 - Gate selector rod
❑ Gate selector rod and AG. Volkswagen AG d
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⇒ page 31
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6 - Securing clip
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❑ Check for firm seating
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7 - Selector rod
❑ Selector rod and selector housing are one unit rrectness of i
❑ Checking function of selector mechanism ⇒ page 34
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❑ Adjusting selector mechanism ⇒ page 31

8 - Coupling rod
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❑ Coupling rod and selector housing are one unit

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1.4 Removing and installing selector mech‐

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♦ T-bar and socket, 10 mm - 3185-
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♦ Assembly tool - T10118-

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– Remove selector lever handle ⇒ page 35 .

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– Disconnect all connectors. op Vo
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– Unscrew nuts -arrows- for selector mechanism -1-.
Note
The illustration shows the selector mechanism of an automatic

gearbox.
Vehicles with rear-wheel drive

– Remove propshaft from gearbox and tie to one side ⇒ Rep.
gr. 39 ; Propshaft; Removing and installing propshaft .
The propshaft is not removed completely.
Vehicles with all-wheel drive
– Remove transfer box ⇒ Rep. gr. 39 ; Transfer box; Removing
and installing transfer box .
Continued for all vehicles

– Unclip and pull off securing clip -4- on gate selector rod -1-,
selector rod -2- and coupling rod -3- using assembly tool -
T10118- .
– Pull gate selector rod, selector rod and coupling rod off gear‐
box and remove selector housing. en AG. Volkswagen AG
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Install in reverse orderutof
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– Always renew securing clips ⇒ Item 6 (page 29) and check for
s
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firm seating.
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spec
es, in part or in w
t to the co
– Install transfer box ⇒ Rep. gr. 39 ; Transfer box; Removing

rrectness of i
– Check function of selector mechanism ⇒ page 34 .

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– Clip in frame for selector lever.

nf
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– Install selector lever handle with cover for gear knob

orm
⇒ page 35 .
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Specified torques
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♦ ⇒ Rep. gr. 39 ; Transfer box; Assembly overview - transfer

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♦ T-bar and socket, 10 mm - 3185-

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The following points are essential to ensure correct adjustment of

selector mechanism:
♦ Moving parts of operating elements and elements that transfer
force must function correctly.
♦ Selector mechanism must move freely.
♦ Gearbox, clutch and clutch mechanism must also be in proper
condition.
• With gearbox in neutral, gear lever must rest in selector lever
gate for 3rd and 4th gear.
Vehicles with black coloured selector housing top part
⇒ page 33
Vehicles with white coloured selector housing top part
– Unclip selector cover -1- from frame using removal wedge -
3409- -arrows-.
– Push selector cover over selector lever.

– Unscrew adjuster screw for gear selection movement -1- and

adjuster screw for gate selection movement -2-.
– Move selector lever in selector lever gate for 3rd and 4th gear
into neutral position.
– First guide locking pin - T10027 A- through hole of selector
housing and then into hole of selector lever.
Note
It must no longer be possible to move selector lever in gear se‐

lection or gate selection directions following locking.
– Tighten adjuster screw for gear selection movement -1- and

adjuster screw for gate selection movement -2- using a multi-
point socket head driver. Tightening torque 12 Nm
– Pull out locking pin - T10027 A-
AG. Volkswagen AG d
– Install cover for selector lever ⇒ page 35 . agen oes
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– Unclip selector cover -1- from frame
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It must no longer be possible to move selector lever in gear se‐

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Unlocking is performed using sliding sleeve -2- for selector lever.
AG.
It is pushed down against spring force.
– Guide screwdriver (4 mm blade) -1- into guide pocket of sliding

sleeve -2- and push downwards until detent lug -4- engages
on lengthways adjuster -3-.
Unlocking is performed using sliding sleeve -2- for gate selector

lever. It is pushed down against spring force.
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– Guide screwdriver (4 mm horblade) -1- into guide pocket of sliding eo
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sleeve -2- and pushsdownwards
s a until detent lug -4- engages ra
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driver -1- until sliding sleeve -3- engages.
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– Pull out locking pin - T10027 A-

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1.6 Checking selector mechanism
AG.
• With gearbox in neutral, gear lever must rest in selector lever

gate for 3rd and 4th gear.
– Operate clutch.
– Select all gears several times. It must be possible to select all
gears without catching. In particular, »smooth shifting« to and
from first and second gears is essential.

If it remains difficult to engage a gear after repeated attempts,

adjust selector mechanism ⇒ page 31 .
1.7 Removing and installing selector lever

handle
♦ Hose clip pliers - V.A.G 1275 A-
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– Remove clamp -arrow-.

– Pull handle off selector lever.
Note
Handle is removed together with selector cover.
Installing
– Push handle with new clamp onto selector lever as far as stop.
– Attach new clamp -arrow- using hose clip pliers - V.A.G 1275- .
1.8 Dismantling and assembling selector

mechanism
Installation position of gearbox selector lever/relay lever
1 - Removing and installing relay lever ⇒ page 36
2 - Removing and installing gearbox selector lever ⇒ page 37
Removing and installing relay lever
The relay lever can also be removed when the gearbox is instal‐
led.
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– Take selector rod -1- off relay lever.

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– Remove hexagon nut -2- from shaft from relay lever -1-.
– Pull off relay lever upwards.
Installing
– Fit relay lever on to shaft with aid of a mirror.
The relay lever is mechanically coded and may only be fitted on
the shaft in one position.
firm seating.
Removing and installing gearbox selector lever
The gearbox selector lever can also be removed when the gear‐
box is installed.
Removing
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– Unclip circlip -4- from selector rod -2- using
hor assembly tool - eo
ut
T10118- and pull off. ss a ra
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– Remove selector rod -2- from gearbox selector lever.

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– Remove hexagon nut -2- from shaft from gearbox selector
l purpos
lever -1-.
– Pull off gearbox selector lever upwards.
nform
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Installing
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– Fit gearbox selector lever on to shaft with aid of a mirror.

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The gearbox selector lever is mechanically coded and may only

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be fitted on the shaft in one position.

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Specified torques
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♦ ⇒ “5.4 Assembly overview - selector unit”, page 55
2 Removing and installing gearbox agen

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⇒ “2.2 Removing gearbox”, page 38 auth eo
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⇒ “2.3 Installing gearbox”, page 43
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2.1 Specified torques for gearbox
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Gearbox to engine
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Specified torques
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spec
Item Bolt Quantity Nm
es, in part or in w
t to the co
1 M12 x 70 3 80
2 M12 x 140 2 80
rrectness of i
3 M10 x 85 3 45
l purpos
A - Dowel sleeves for centring

Gearbox mounting on body and gearbox ⇒ page 45
nform
mercia
at
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ion
2.2 Removing gearbox
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Special tools and workshop
for
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equipment required
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♦ Adapter - 2024 A/1- agen

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♦ Engine and gearbox jack - V.A.G 1383 A- has been discon‐
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tinued; use engine and gearbox jack - VAS 6931- instead
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♦ Assembly tool - T10118-

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♦ Clutch plate spline grease ⇒ Electronic parts catalogue (ET‐ co Vo
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Procedure
– Disconnect earth strap at battery with ignition switched off ⇒
Electrical system; Rep. gr. 27 ; Battery; Disconnecting and
connecting battery .
– Raise vehicle.
– If fitted, remove underbody guard ⇒ General body repairs,
exterior; Rep. gr. 66 ; Noise insulation .
– Remove propshaft ⇒ Rep. gr. 39 ; Propshaft; Removing and
– Remove rear propshaft ⇒ Rep. gr. 39 ; Propshaft; Removing
and installing propshaft .
– Remove front propshaft ⇒ Rep. gr. 39 ; Propshaft; Removing
and installing propshaft .
2. Removing and installing gearbox 39

Vehicles with selectable all-wheel drive

– Detach connector -arrows- and unclip wiring harness from
transfer box.
AG. Volkswagen AG d
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– Pull breather line -arrow- off transfer box.
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– Clamp off hose of pipe/hose line -1- to clutch slave cylinder
om
using hose clamp up to 25 mm - 3094- .
n in
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– Pull out clips -arrows- and pull breather -2- off gearbox.
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Do not operate clutch pedal any more. rig ht
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– Pull off connector -arrow- from reversing light switch - F4- .

– Pull electrical wiring harness off gearbox.

– Remove bracket for exhaust pipe with catalytic converter or

diesel particulate filter -1-.
AG. Volkswagen AG d
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It is not necessary to unfasten starter cables. ss a c
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– Unbolt starter from engine/gearbox and secure as necessary
itte
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⇒ Electrical system; Rep. gr. 27 ; Starter; Removing and in‐
erm
ab
stalling starter .
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Note
spec
es, in part or in w
t to the co
If the engine is already supported by the support bracket -
10-222A- , the engine does not need to be supported additionally
by the engine support - T50015- .
rrectness of i
l purpos
– Secure adapter - 2024 A/1- on subframe with fitting tool -

3046- .
nform
ercia
– Secure engine support - T50015- with commercially available

m
bolts -1 and 2-, and pretension it slightly by turning.
at
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Gearbox cross member, Version A
or
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– Unscrew bolt -1-.

– Place engine and gearbox jack - VAS 6931- under gearbox

cross member.
– Unscrew bolts -2-.
– Lower gearbox cross member -1- using engine and gearbox
jack , and remove it.
Gearbox cross member, Version B
G. Volkswagen AG d
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– Remove securing bolts for gearbox cross member -1-.
s
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– Lower gearbox cross member with engine and gearbox jack -
an
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rm
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– Unclip and pull off securing clip -4- on gate selector rod -1-,
selector rod -2- and coupling rod -3- using assembly tool -
rrectness of i
T10118- .
l purpos
– Pull gate selector rod, selector rod and coupling rod off gear‐
box.
nform
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tion in
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– Remove engine/gearbox connecting bolts -1…3- except for
t
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Note
First remove connecting bolt on engine side.

– Place engine and gearbox jack - V.A.G 1383 A- or engine and

gearbox jack - VAS 6931- under gearbox.
– Secure gearbox on engine and gearbox jack - VAS 6931- us‐
ing securing strap.
– Remove last engine/gearbox connecting bolt.
– Press gearbox off engine (dowel sleeves) and pull out to rear.
2.3 Installing gearbox

Note
♦ Renew self-locking nuts and bolts.

♦ All cable ties which were opened or cut during removal must
be renewed at the same locations.
♦ Check whether dowel sleeves
wage
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are fitted in cylinder
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♦ If dowel sleeves
tho
ris are not fitted, difficulties shifting gears, nclutch
tee
problemss aand possible noises from the gearbox (rattling of r ac
u o
gears which
s are not engaged) could occur.
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Caution
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Please observe the following points during all installation work,

h re
ole,
in particular in the engine compartment, due to the space lim‐

spec
itations:
t to the co
♦ Route lines of all kinds and electrical cables so as to re-

establish the original wiring.
rrectne
♦ Make sure there is adequate clearance from all moving or

hot parts.
ss o
cial p
f in
– Check clutch release bearing with hydraulic actuation for

form
mer
wear. Renew component if necessary ⇒ page 12 .

atio
m
– Clean input shaft splines and apply thin coat of clutch plate
o
n
c
i
or
spline grease ⇒ Electronic parts catalogue (ETKA) .

thi
te
sd
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The clutch plate must slide easily to and fro on the input shaft.
i
o
pr
cum
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fo
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– Check for proper seating of both dowel sleeves between en‐

ng
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gine and gearbox. t. Cop py
rig
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– Ensure that intermediate plate is correctly seated on engine. pyri by
Vo
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Prote AG.

– Fit gearbox onto engine and gearbox jack - V.A.G 1383 A- or

engine and gearbox jack - VAS 6931- .
– Secure gearbox on engine and gearbox jack - VAS 6931- us‐
ing securing strap.
Specified torques
♦ ⇒ “3.1 Assembly overview - assembly mountings, version A”,
page 45
♦ ⇒ “3.2 Assembly overview - assembly mountings, version B”,
page 47
♦ ⇒ Electrical system; Rep. gr. 27 ; Starter; Assembly overview
- starter
♦ ⇒ Rep. gr. 26 ; Emission control system; Assembly overview
- emission control system
♦ ⇒ Rep. gr. 39 ; Propshaft; Assembly overview - propshaft
♦ Removing and installing retaining frame; Assembly overview
- retaining frame ⇒ General body repairs, exterior; Rep. gr.
51 ; Removing and installing retaining frame; Assembly over‐
. Volkswagen AG
view - retaining frame kswagen AG does
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es, in part or in w
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rrectness of i
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or
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3 Assembly mountings
⇒ “3.1 Assembly overview - assembly mountings, version A”,
page 45
⇒ “3.2 Assembly overview - assembly mountings, version B”,
page 47
⇒ “3.3 Removing and installing gearbox mountings, version B”,
page 48
3.1 Assembly overview - assembly mountings, version A
1 - Engine mounting
❑ Left
⇒ Rep. gr. 10 ; Assem‐
bly mountings; Remov‐
ing and installing engine
mounting
2 - Bolts
❑ Qty. 4
❑ Specified torque ⇒ Rep.
gr. 10 ; Assembly
mountings; Assembly agen
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3 - Bolts aut ra
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❑ Qty. 3
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gr. 10 ; Assembly
ot
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mountings; Assembly
, is n
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overview - assembly
hole
mountings
spec
es, in part or in w
t to the co
4 - Engine support
❑ Left
❑ Removing and installing rrectness of i
l purpos
block, pulley end; Re‐

moving and installing
engine support
nform
ercia
5 - Nuts
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com

ion in
r
❑ Qty. 2
te o
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❑ Specified torque ⇒ Rep. gr. 10 ; Assembly mountings; Assembly overview - assembly mountings
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❑ Specified torque ⇒ Rep. gr. 10 ; Assembly mountings; Assembly overview - assembly mountings Prote
cted AG.
agen
7 - Adapter
❑ Left
❑ For engine support
❑ Removing and installing ⇒ Rep. gr. 13 ; Cylinder block, pulley end; Removing and installing engine
support
3. Assembly mountings 45
ks wage es
8 - Engine support Vol
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❑ Right orise nte
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u ra
c and installing engine
support
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9 - Bolts itte
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10 - Engine mounting
es, in part or in w
t to the co
❑ Right
❑ Removing and installing ⇒ Rep. gr. 10 ; Assembly mountings; Removing and installing engine mounting
rrectness of i
11 - Gearbox mounting
l purpos
❑ Removing and installing ⇒ Rep. gr. 10 ; Assembly mountings; Removing and installing gearbox mounting
12 - Bolts
nf
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❑ Qty. 4
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13 - Cross member
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14 - Bolts
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❑ Renew after removal t. Cop py
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❑ Qty. 4
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❑ 50 Nm +45°
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Prote AG.
15 - Bolts
❑ Qty. 4
❑ 50 Nm +90°
16 - Bolts
❑ Qty. 4
17 - Bolts
❑ Qty. 2
❑ 20 Nm +90°

3.2 Assembly overview - assembly mountings, version B
1 - Bolts
AG. Volkswagen AG d
❑ Qty. 3 ksw
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❑ Specified d b torque ⇒ Rep.
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mountings;
s aut
Assembly ra
c
overview
s - assembly
ce
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mountings
un
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2 - Bolts
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ility
❑ Qty. 4
ot
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gr. 10 ; Assembly
hole
spec
mountings; Assembly
es, in part or in w
overview - assembly
t to the co
mountings
3 - Engine mounting
rrectness of i
❑ Left
l purpos

⇒ Rep. gr. 10 ; Assem‐
bly mountings; Remov‐
nform
ercia
ing and installing engine

m
mounting
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tion in
4 - Engine support
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❑ Left
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block, pulley end; Re‐
t. Cop py
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rig
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engine support
cop Vo
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5 - Nuts
AG.
❑ Qty. 2
gr. 10 ; Assembly
mountings; Assembly
overview - assembly
mountings
6 - Bolts
❑ Qty. 3
7 - Adapter
❑ Left
❑ For engine support
support
8 - Engine support
❑ Right
support
9 - Bolts
❑ Qty. 4
10 - Engine mounting
❑ Right
❑ Removing and installing ⇒ Rep. gr. 10 ; Assembly mountings; Removing and installing engine mounting
11 - Gearbox cross member
12 - Bolts
❑ Qty. 4
❑ 50 Nm +90°
13 - Gearbox mounting
❑ Removing and installing ⇒ Rep. gr. 10 ; Assembly mountings; Removing and installing gearbox mounting
14 - Bolts
❑ Qty. 4
15 - Bolts
❑ Qty. 4
AG. Volkswagen AG d
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3.3 Removing and installing gearbox ol not
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mountings, version B ris nte
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Special tools and workshop equipment required s
ce
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un
pt
♦ Engine and gearbox jack - VAS 6931- an
d
itte
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erm
ab
ility
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spec
t to the co
rrectness o
cial p
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Removing lkswage es n
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– Raise vehicle. ir se
d b ran
tee
tho
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– Mark installations aposition
u of gearbox cross member. ac
s
ce
le
– Unscrew securing bolts for gearbox mountings -arrows-. un
pt
an
d
itte
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rm
ab
pe
ility
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, is n
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hole
spec
es, in part or in w
t to the co
– Place engine and gearbox jack - V.A.G 1383 A- or engine and
gearbox jack - VAS 6931- under gearbox.
rrectness of i
– Remove securing bolts for gearbox cross member -1- and
l purpos
gearbox mounting -arrows-.

– Remove gearbox cross member with gearbox mounting.
nform
ercia
Installing
m
a
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tion in
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Arrow on gearbox cross member points in direction of travel.
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Note
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♦ Carefully clean and/or degrease gearbox cross member be‐ cop Vo
by lksw
fore installing. Then protect against corrosion as follows: cted agen
Prote AG.
♦ Apply new primer and new paint on all “bare metal” and “dam‐
aged” paint surfaces of gearbox cross member (with a spray
can or brush).
♦ After installation, apply corrosion protection (wax) all over
gearbox cross member.
– Insert gearbox cross member back into previously marked po‐

sition.
Note
♦ Securing bolts -1- are stretch bolts and must be renewed.

♦ Securing bolts -1- are not allowed to be tightened with an im‐
pact driver.
Specified torques
♦ ⇒ page 47
4 Transporting gearbox
♦ Workshop hoist - VAS 6100-
AG. Volkswagen AG d
agen oes
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♦ Lifting tackle - 2024 A- d by
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– Attach lifting tackle - 2024 A- as follows to lifting eyes of gear‐
box and transport using workshop hoist - VAS 6100- .
l purpos
Input shaft side:
nf
ercia
Fourth hole of hook rail in position 1 of lifting tackle
orm
-arrow B-.
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Output shaft side:
or c
thi
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First hole of hook rail in position 8 of lifting tackle -arrow A-.

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The hooks and locating pins must be secured with locking pins! yri
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Prote AG.

5 Dismantling and assembling gearbox

⇒ “5.1 Schematic overview - gearbox”, page 51
⇒ “5.2 Assembly overview - clutch housing and input shaft”, page
52
⇒ “5.3 Assembly overview - gearbox housing, layshaft, output
shaft and selector unit”, page 53
⇒ “5.4 Assembly overview - selector unit”, page 55
⇒ “5.6 Removing and installing propshaft flange”, page 57
⇒ “5.7 Removing and installing adapter shaft”, page 59
⇒ “5.8 Dismantling and assembling gearbox”, pagege61
n AG. Volkswagen AG d a oes
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5.1 Schematic overviewis-edgearbox
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1 - Input shaft
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❑ With splines for 4th gear
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2 - 4th gear
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h re
hole
spec
3 - 3rd gear
es, in part or in w
t to the co
4 - Selector shaft
❑ With locking device and
selector forks
rrectness of i
5 - 2nd gear
l purpos
6 - 1st gear
nf
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7 - Reverse gear
orm
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8 - Selector unit
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❑ (selector shaft)
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9 - Adapter shaft
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❑ Adapter shaft in four-

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wheel drive vehicles

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❑ Propshaft flange in rear-
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10 - Output shaft Prote AG.
11 - Gearbox housing
12 - Layshaft
13 - 5th gear
14 - 6th gear
15 - Gear of constant mesh
gear pair
16 - Clutch housing
5. Dismantling and assembling gearbox 51

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Amarok 2011 ➤ , Amarok 2017 ➤ olks
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5.2 Assembly overview - clutch housing and input shaft
a c
ss
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un
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1 - Clutch housing
erm
ab
ility
❑ Servicing ⇒ page 79
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2 - Locking bolt
h re
ole,
spec
❑ For selector shaft
❑ 45 Nm
t to the co
3 - Oil filler plug
❑ 35 Nm
rrectne
4 - Oil drain plug
ss
❑ 35 Nm
o
cial p
f in
5 - Plug
form
mer
❑ Installed in some gear‐
atio
m
boxes
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6 - Inner race
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❑ For double deep groove

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7 - Shim C py
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❑ (M10 x 1.25) Prote AG.
❑ Insert with locking fluid

⇒ Electronic parts cata‐
logue (ETKA)
❑ 30 Nm
9 - Cap
❑ For layshaft.
⇒ page 61
10 - Seal
❑ For input shaft
❑ Renewing ⇒ page 104
11 - Input shaft

5.3 Assembly overview - gearbox housing, layshaft, output shaft and selector
unit
1 - Bolt n AG. Volkswagen AG do

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❑ For securingy Vyoke olks to se‐ ot g
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lector shaft
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❑ Different
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h versions; Allo‐ or
ac
cate
ss according to ⇒
Electronic parts cata‐
ce
le
un
pt
logue (ETKA) .
an
d
itte
y li
❑ Specified torque
erm
ab
ility
⇒ page 56
ot p
wit
is n
2 - Follower
h re
ole,
spec
❑ Different versions; Allo‐
cate according to ⇒
t to the co
logue (ETKA) .
rrectne
3 - Bolt
❑ Qty. 9
ss
❑ 23 Nm
o
cial p
f in
4 - Selector unit
form
mer
❑ Dismantling and assem‐

atio
m
bling ⇒ page 55
o
n
c
i
or
n thi
5 - Propshaft flange
te
sd
va
❑ For vehicles with rear-

i
o
pr
cum
r
wheel drive
fo
en
ng
t.
yi
Co
Cop py
⇒ page 57
t. rig
gh ht
pyri by
Vo
o
6 - Bolt
c by lksw
cted agen
Prote AG.
❑ Vehicles with rear-
wheel drive
❑ Insert with locking fluid
and sealant ⇒ Electron‐
ic parts catalogue (ET‐
KA)
❑ 120 Nm
7 - Shim
❑ For vehicles with rear-wheel drive
❑ Insert with sealant ⇒ Electronic parts catalogue (ETKA)
8 - Bolt
❑ Insert with locking fluid and sealant ⇒ Electronic parts catalogue (ETKA)
❑ 120 Nm
9 - Adapter shaft
❑ For transfer box
❑ Vehicles with all-wheel drive
10 - Seal
❑ For output shaft
11 - Reversing light switch - F4-
❑ 20 Nm

Amarok 2011 ➤ , Amarok 2017w➤ agen
AG. Volkswagen AG d
oes
ks not
6-speed manual gearbox b0C6
y V - Edition 06.2019
ol
gu
a
ed ran
oris tee
12 - Bolt au
th or
ac
ss
❑ For gearbox housing to clutch housing
ce
le
un
pt
❑ Qty. 17
an
d
itte
y li
❑ 23 Nm erm
ab
ility
ot p
13 - Washer
wit
is n
h re
14 - Spacer ring
ole,
spec
❑ Set on roller bearing in gearbox housing before inserting layshaft
t to the co
15 - Solenoid
❑ Clean
rrectne
❑ Insert in housing ribs
16 - Layshaft
ss o
❑ Dismantling and assembling ⇒ page 109
cial p
f inform
17 - Dowel sleeve
mer
atio
❑ Qty. 2
om
n
c
i
❑ Always insert into gearbox housing
or
n thi
te
sd
va
i
o
pr
cum
r
fo
19 - Roller bearing
en
ng
t.
yi Co
op
❑ For supporting input shaft on output shaft C py
t. rig
gh ht
❑ Observe installation position yri
p by
co Vo
by lksw
❑ Insert in input shaft before fitting clutch housing onto gearbox housing cted agen
Prote AG.
20 - 4th gear clutch body

21 - Synchro-ring for 4th gear
22 - Output shaft
❑ Dismantling and assembling ⇒ page 89
23 - Selector fork assembly
❑ Insert in locking collars of output shaft and layshaft
❑ ⇒ page 56

AG. Volkswagen AG d
agen oes Amarok 2011 ➤ , Amarok 2017 ➤
olksw not
d byV 6-speed manualgu gearbox 0C6 - Edition 06.2019
ara
ise nte
or eo
h
ut
5.4 Assembly overview - selector unit ss a ra
c
ce
le
un
pt
an
d
itte
1 - Hexagon nut
y li
erm
ab
❑ Self-locking
ility
ot p
wit
is n
h re
ole,
❑ 23 Nm
spec
2 - Gearbox selector lever
t to the co
❑ Install so that master
spline aligns with selec‐
tor shaft.
rrectne
⇒ page 36
ss o
cial p
f inform
3 - Protective cap
mer
atio
m
❑ Remove e.g. with three-

o
n
c
arm puller - VAS 251
i
or
n thi
203- (Kukko 30-1) to
te
sd
va
avoid damage
i
o
pr
cum
r
fo
4 - Seal
en
ng
t.
yi Co
op
❑ For rotary gear selector C py
ht. rig
shaft or rotary gate se‐ rig ht
py by
lector shaft co Vo
by lksw
cted agen
❑ Carefully remove with
Prote AG.
extractor hook -
T20143/1- , for exam‐
ple; Do not damage ro‐
tary gear selector shaft
or rotary gate selector
shaft while doing so.
❑ Installing ⇒ page 56
5 - Pin for coupling rod
❑ 20 Nm
6 - Selector mechanism cover
7 - Rotary gear selector shaft
❑ Fitting position ⇒ page 56
8 - Rotary gate selector shaft
9 - Breather filter
❑ 10 Nm
10 - Relay lever
❑ Install so that master spline aligns with selector shaft.

Driving in seal -A- for rotary gear selector shaft and rotary gate
selector shaft
– Lightly oil new oil seal on outer diameter. Fill space between
sealing lips half full with sealing grease .
AG. Volkswagen AG d
– Drive in seal using tube - VW 420- . agen oes
olksw not
y V gu
d b ara
rise nte
ho eo
Note s aut ra
c
s
ce
e
nl
♦ Fit guide sleeve - T50058- with rotary gear selector shaft and
pt
du
an
rotary gate selector shaft -B- installed in order to protect the
itte
y li
erm
seal.
ab
ility
ot p
♦ Use guide sleeve - T50058- to install the rotary gear selector
wit
, is n
shaft and rotary gate selector shaft -B- in selector mechanism
h re
hole
cover.
spec
es, in part or in w
t to the co
Installation position of rotary gear and gate selector shafts in se‐
lector mechanism cover
rrectness of i
1- Rotary gate selector shaft
l purpos
2- Rotary gear selector shaft

3- Bleeder
nform
ercia
– Insert rotary gate selector shaft -1- and rotary gear selector
m
at
om
i
shaft -2- in selector mechanism cover as shown in illustration.
on
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
op
5.5 Assembly overview - selector forks
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
♦ The selector forks with selector shaft and locking device form one unit and can only be renewed together.
♦ The individual selector fingers for the respective selector fork are located on the selector shaft.
♦ The locking elements for the selector fork are located in the gearbox and clutch housing and cannot be
renewed individually.

1 - Countersunk bolt
❑ For securing yoke to se‐
lector shaft
❑ Installed in gearboxes
up to 06.2012
❑ Allocation ⇒ Electronic
parts catalogue (ETKA)
❑ 23 Nm
2 - Follower
up to 06.2012
3 - Fitted bolt
❑ For securing yoke to se‐
lector shaft
as of 06.2012 AG. Volkswagen AG d
agen
❑ Allocation ⇒VoElectronic
lksw
oes
not
gu
parts catalogue
ed by (ETKA) ara
nte
ris
❑ 23 Nm ut
ho eo
r
a ac
ss
4 - Follower
ce
le
un
pt
an
d
itte
y li
as of 06.2012
rm
ab
pe
ility
ot

wit
, is n
h re
hole
5 - Selector fork for reverse

spec
gear
es, in part or in w
t to the co
6 - 1st/2nd gear selector fork

7 - Selector fork for 5th and 6th
rrectness of i
gear
l purpos
8 - 3rd/4th gear selector fork

9 - Selector shaft
nform
ercia
10 - Locking device
m
a
com
tion in
r
te o
thi
5.6 Removing and installing propshaft

s
iva
do
r
rp
flange
um
fo
en
ng
t.
yi Co
Vehicles with rear-wheel drive t. Cop py
rig
gh ht
yri
p by
o Vo
by c lksw
cted agen
♦ -2- puller - VAS 251 417 - (Kukko 18-1)
Prote AG.

♦ Thrust piece - VW 431-
♦ Counterhold - 3145- (modifying holes ⇒ page 59 )
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
♦ Torque wrenchho- V.A.G 1332-
ris nte
eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
♦ Bolt M12 x 1.5 mm (120 mm in length)

l purpos
♦ Locking fluid ⇒ Electronic parts catalogue (ETKA)

nf
ercia
♦ Sealant ⇒ Electronic parts catalogue (ETKA)

orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Modify counterhold - 3145-

• Counterhold - 3145- is used to loosen and tighten securing nut
for propshaft flange. Therefore, drill out both holes in counter‐
hold - 3145- to dimension -a- = ∅ 10.5 mm.
Note
A new counterhold - 3145- with ∅ 10.5 mm holes will be supplied.
Removing
– Screw counterhold - 3145- onto propshaft flange.
– Remove bolt for propshaft flange.
– Screw bolt M12 x 1.5 mm (120 mm in length) into output shaft.
AG. Volkswagen gen AG do
swa es n
– Fit puller - VAS 251 417 - (Kukko 18-1)bwith
y V thrust piece - VW
olk ot g
ua
431- . ris
ed ran
tee
tho or
– Pull propshaft flange off outputsshaft.
au ac
s
ce
le
Installing
un
pt
an
d
itte
y li
erm
ab
ility
– Use a thread chaser (thread tap), for example, to clear residual
ot p
wit
locking fluid from threaded hole in output shaft.
is n
h re
ole,
– Apply locking fluid to thread of bolt for propshaft flange ⇒
spec
Electronic parts catalogue (ETKA) .
t to the co
– Apply a bead of sealant under bolt head and under washer
(gearbox side) ⇒ Electronic parts catalogue (ETKA) .
rrectne
– Insert bolt for propshaft flange with washer and tighten it.
ss
o
cial p
f inform
Specified torques
mer
atio
♦ ⇒ “5.3 Assembly overview - gearbox housing, layshaft, output

om

c
i
or
n thi
te
sd
va
5.7 Removing and installing adapter shaft

i
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
Special tools and workshop equipment required rig ht
py by
co Vo
by lksw
♦ Two-arm puller - VAS 251 001- (Kukko 20-10) -1- Prote
cted AG.
agen

♦ Counterhold - T10322- (gearbox removed)
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
♦ Torque wrench - V.A.G
ut
ho 1332- eo
ra
s a c
s
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
rrectne
♦ Bolt M12 x 1.5 mm (140 mm in length)

ss o
cial p

f inform
mer

atio
m
Removing
o
n
c
i
or
n thi
e
Gearbox is removed.
t
sd
iva
o
pr
– Engage 1st gear.

um
r
fo
en
ng
t.
yi
– Hold input shaft tight using counterhold - T10322- .
Co
Cop py
t. rig
Gearbox installed
gh ht
pyri by
Vo
o
by c lksw
– Remove transfer box ⇒ Rep. gr. 39 ; Transfer box; Removing cted agen
Prote AG.
– Engage 1st gear.
Continuation for all
– Remove bolt for adapter shaft ⇒ Item 8 (page 53) .

– Screw bolt M12 x 1.5 mm (140 mm in length) -A- into output

shaft.
– Fit two-arm puller - VAS 251 001- (Kukko 20-10) -B- with thrust
piece - VW 431- .
– Pull adapter shaft off output shaft.
Installing
n AG. Volkswagen A
– Use a thread chaser olks
w(thread
age tap), for example,
G do
es n to clear residual
o
locking fluid dfrom
by
V threaded hole in output shaft.t guar
e an
ris te
– Apply locking
ut
ho fluid ⇒ Electronic parts catalogue (ETKA)
e o to
ra
thread
ss of bolt for adapter shaft ⇒ Item 8 (page 53) and a bead
a c
of sealant ⇒ Electronic parts catalogue (ETKA) under bolt
ce
le
un
pt
head.
an
d
itte
y li
erm
– Insert bolt for adapter shaft and tighten it.
ab
ility
ot p
wit
is n
h re
ole,
spec
Specified torques
t to the co
rrectne
5.8 Dismantling and assembling gearbox ss o

cial p
f in
Removing and installing clutch housing, selector unit, output

form
mer
shaft, layshaft, and selector forks

atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


equipment required
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
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
i
or
n thi
e
♦ Drift sleeve - VW 244 B-

t
sd
iva
o
pr
♦ Tube - VW 415 A- cum

r
fo
en
ng
t.
yi
♦ Thrust plate - VW 447 i-
Co
Cop py
t. rig
gh
♦ Drift - VW 460/2- from removing tool - VW 460-
ht
pyri by
Vo
co lksw
by
♦ Removal tool - VW 681-
cted agen
Prote AG.
♦ Hook - 10 - 222 A /2-

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
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
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Thrust plate - 40 - 105-

♦ Assembly tool - 3301-
♦ Engine and gearbox support - VAS 6095-
♦ Workshop hoist - VAS 6100-
♦ Drip tray for workshop hoist - VAS 6208-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
♦ Puller - T10055-
y li
erm
ab
ility
♦ Gearbox support - T10321-

ot p
wit
, is n
♦ Counter-hold tool - T10322-

h re
hole
spec
♦ Support bridge - T10323-

es, in part or in w
t to the co
♦ Guide pin - T10341-

♦ Extractor hook - T20143-
rrectness of i
♦ Inductive heater - VAS 6414-

l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

♦ Thrust piece - T50068-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
ut ra
♦ Support element - T50056- ss a c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
♦ Lifting tool - T50057-

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
♦ Heating drift - T50060- olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
♦ Self-tapping screw, approx. ∅ 4 mm
nform
ercia
Dismantling gearbox
m
at
om
– Place drip tray for workshop hoist - VAS 6208- below gearbox.
ion
c
in t
or
– Drain gear oil.
his
ate
do
riv
– Secure gearbox to gearbox support - T10321- using bolts

p
cum
or
-A-, and secure it in engine and gearbox support - VAS 6095- .

f
en
ng
t.
yi Co
op
– Remove clutch release mechanism ⇒ page 12 . C py
t. rig
gh ht
yri by
– Remove adapter shaft or propshaft flange from gearbox. cop Vo
by lksw
cted agen
Prote
♦ Remove adapter shaft ⇒ page 59 .
AG.
♦ Remove propshaft flange ⇒ page 57 .
– Using oil seal extractor lever - VW 681- or extractor hook -

T20143/2- carefully remove seal of output shaft.

Removing cap for layshaft

– To pull out sealing cover, screw a sheet metal screw of about
4 mm in diameter -A- into outer area of sealing cover.
Note AG. Volkswagen AG d

agen oes
olksw not
yV gu
Do not screw in sheet metal iscrew
sed b too far to avoid damaging ara
nte
bearing behind it. hor eo
aut ra
ss c
– Pull out sealing cover using puller - T10055- .
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
– Counterhold input shaft with counter-hold tool - T10322- . To
ot
do this, screw a bolt -C- into clutch housing, and make sure
wit
, is n
h re
that sliding handle -D- rests against the bolt.
hole
spec
– Then unscrew bolt -A- from layshaft, and remove washer -B-.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tio
– Unscrew locking bolt -A- for selector shaft and bolts -B- se‐
n in
r
curing gearbox housing to clutch housing.

te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Install support bridge - T10323- to clutch housing -1-.

– Fit drift - VW 460/2- onto layshaft, and pull off clutch housing.

– Remove roller bearing -1- from output shaft.

Clutch body -2- with synchro-ring for 4th gear remains installed
on output shaft.
– Remove reversing light switch - F4- -arrow-.
AG. Volkswagen AG d
agen o
– Unscrew bolts -arrows-
yV
olks securing selector unit s-A-
w e n
ot gto gearbox.
b ua
ed ran
– Carefully lever
ho
ris off selector unit -A-. tee
t or
au a
Do not damage
ss sealing surfaces of gearbox housing and selector
c
unit while doing so.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Unscrew bolt -A-.

rrectness of i
– Remove yoke -B- from selector shaft.

l purpos
Note
nf
ercia
orm
m
atio
♦ On gearboxes up to 06.2012 guide yoke lug -arrow- out of

om
track -C-.
n in
or c
thi
e
♦ On gearboxes as of 06.2012, the track is located below the

t
sd
iva
yoke.
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen o
– Install support
Vol bridge - T10323- to gearboxothousing.
ksw es n
g
by ua
ed ran
• Gearbox
ho
ris be vertical in repair stand. tee
t or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Then, secure lifting tool - T50057- with knurled screw -arrow-
rrectness of i
to layshaft.
l purpos
– Using hook - T50057- , attach lifting tool - VAS 6100- to work‐

shop hoist - 10 - 222 A /2- .
nform
ercia
– Using spindle of support bridge - T10323- , push set of shafts

upwards.
m
at
om
ion
c
in t
or
his
e
Note
at
do
priv
cum
or
Ensure that the lifting tool - T50057- is properly attached to the

f
en
ng
workshop hoist - VAS 6100- .

t.
yi Co
Cop py
ht. rig
rig ht
– Reposition workshop hoist - VAS 6100- alternately when
py by
co Vo
by lksw
pushing the set of shafts upwards.
Prote
cted AG.
agen
– Using workshop hoist - VAS 6100- , raise set of shafts out of

gearbox housing.

– Then, place set of shafts into support - T50056- .

– Remove lifting tool - T50057- from set of shafts -1-.
– Remove selector fork assembly -2-.
Note
The output shaft can be pulled off the layshaft sideways using the
adjustment range -arrow- of the support .
– Remove ball bearing for output shaft from gearbox housing

⇒ page 76 .
– Remove seal for input shaft from clutch housing
⇒ page 104 .
– Remove ball bearing for input shaft from clutch housing
⇒ page 79 .
– Clean sealing surfaces of gearbox housing and clutch hous‐
ing.
Assembling gearbox
• New ball bearing ⇒ Item 13 (page 77) for output shaft is in‐
stalled in gearbox housing.
• The new ball bearing ⇒ Item 1 (page 79) for the input shaft
is installed in the clutch housing.
– Use a thread chaser (thread tap) M10 x 1.25, for example, to
clear residual locking fluid from threaded hole in layshaft.
– The set of shafts -1- is inserted in support - T50056- .

– Insert selector fork assembly -2- in locking collars of shafts. n AG. Volkswagen A
G do
wage es n
The clutch body with synchro-ring for 4th gear is fitted bon olks
y V output
ot g
ua
shaft. rised ran
te
tho eo
s au ra
c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Install lifting tool - T50057- to set of shafts, and secure it to

layshaft using knurled screw -arrow-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
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itte
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Note
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spec
es, in part or in w
♦ The selector forks in the locking collars must be set to neutral
t to the co
position.
♦ The recess in the locking device -2- must be fitted onto the lug
of the 3rd/4th gear selector fork -1- -arrow-. rrectness of i
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• The gearbox housing must be in vertical position in the as‐
by lksw
cted agen
Prote
sembly stand, and the dowel sleeves -1- must be installed.
AG.
• The reverse gear wheel -2- and the magnet -3- must be in‐
stalled.
• The spacer ring -4- must be placed on the roller bearing for
the layshaft.
• Heat the heating tool - T50060- with inductive heater - VAS
6414- , for example, to approx. 80°C, and insert it in inner
bearing race of new ball bearing -5-. Do not heat the ball bear‐
ing with a hot air blower.

– Using hook - T50057- , attach lifting tool - VAS 6100- to work‐

shop hoist - 10 - 222 A /2- .
– Carefully insert set of shafts in gearbox housing.
Note
Mesh teeth of layshaft and reverse gear wheel.
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hole
– Then secure special tools to output shaft, as shown in illus‐
spec
tration.
es, in part or in w
t to the co
– Screw spindle - 3346/2- by hand as far as stop into threaded
hole of output shaft.
rrectness of i
– Pull in set of shafts as far as stop by turning nut - 3346/3- .
l purpos
Note
nf
ercia
orm
The set of shafts remains secured by the workshop hoist - VAS

m
atio
m
6100- while doing so. Reposition workshop hoist as necessary

o
n in
c
while pulling in component.

or
thi
te
sd
iva
– Then remove workshop hoist - VAS 6100- and lifting tool -

r
rp
cu
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T50057- from layshaft.

f
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op
The clutch body with synchro-ring for 4th gear must be installed C py
t. rig
to the output shaft ⇒ page 68 .
gh ht
pyri by
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by
– Turn gearbox housing in assembly stand to horizontal posi‐ cted agen
Prote AG.
tion.
– Moisten roller bearing -1- with gear oil, and insert it in input
shaft -2-.
• Installation position of roller bearing -1-: the smaller diameter
of the plastic cage -arrow- faces towards input shaft -2-.

AG . Volkswagen AG
– Screw guide pins - T10341- into 2 opposing threaded
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agenholes of does
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clutch housing -1-. by
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– Apply sealant ⇒ Electronic parts catalogue
ut
ho
r
(ETKA) evenly to eo
sealing surface of gearbox housing.
ss a ra
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– Carefully fit clutch housing.
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Note
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♦ Slightly turn the input shaft while doing so, so that the clutch
hole
spec
body ⇒ page 68 properly engages in the splines of the input
es, in part or in w
shaft.
t to the co
♦ The roller bearing must not fall out of the input shaft.
rrectness of i
l purpos
nform
mercia
a
– Tighten connecting bolts -B- securing gearbox housing to
com
tion in
clutch housing to specified torque. Remove guide pins -
r
te o
T10341- while doing so.
thi
s
iva
do
– Tighten locking bolt -A- for selector shaft.
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– Move selector shaft to neutral.

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Cop py
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cted agen
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– Install yoke -B- to selector shaft, and tighten bolt -A-.
Note
♦ On gearboxes up to 06.2012 insert yoke lug -arrow- in track

-C-.
♦ On gearboxes as of 06.2012, the track is located below the
yoke.
– Apply sealant ⇒ Electronic parts catalogue (ETKA) evenly to

sealing surface of selector unit.

– Fit selector unit -A-, guiding rotary gear selector shaft and ro‐
tary gate selector shaft into yoke of selector shaft.
– Tighten bolts -arrows- to specified torque.
AG. Volkswagen AG d
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– Secure reversing light switch - F4- -arrow-.
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
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om
n
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– Heat up outer inner race for double deep groove ball bearing
iv
o
pr
c
to approx. 100°C and place on layshaft. If necessary, drive on
um
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fo
inner race onto stop.
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Cop py
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– Fit plate -B-.

– Clean thread of bolt -A- with a wire brush. Then insert bolt with
locking fluid .
– Counterhold input shaft with counter-hold tool - T10322- . To
do this, screw a bolt -C- into clutch housing, and make sure
that sliding handle -D- rests against the bolt.
– Tighten bolt -A- to specified torque.
– Lightly oil outer circumference of new sealing cover for lay‐
shaft before installing it.

– Drive in new layshaft sealing cover up to stop with tube - VW

415 A- and thrust plate - VW 447 i- , taking care that sealing
cover is not canted.
lkswage es n
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– Lightly oil outer circumference
th o of seal for input shaft, and half- tee
or
fill space between sealing
ss
au
lips -arrow- with grease . ac
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spec
es, in part or in w
t to the co
rrectness of i
– Drive in new seal of input shaft to stop on tool using press tool
l purpos
- T50038- .
– Install clutch release mechanism ⇒ page 12 .
nform
ercia
– Lightly oil outer circumference of new seal for output shaft, and
m
at
om
half-fill space between sealing lips with sealing grease .

ion
c
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or
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ate
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cum
for
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Prote
– Drive in new seal of output shaft to stop on tool using press
AG.
tool - T50068- .
– Mount adapter shaft or propshaft flange on gearbox:
♦ Installing adapter shaft ⇒ page 59
♦ Installing propshaft flange ⇒ page 57
– Shift through all gears.
Specified torques
♦ ⇒ “1.2 Assembly overview - clutch release mechanism”, page
12
♦ ⇒ “5.2 Assembly overview - clutch housing and input shaft”,
page 52

6 Gearbox housing, clutch housing

⇒ “6.1 Assembly overview - gearbox housing”, page 76
⇒ “6.2 Assembly overview -aclutch
gen AG housing”,n A
. Volkswage page
G do 79
w es n
olks ot g
⇒ “6.3 Repairing gearbox
ed
by
V
housing”, page 79 ua
ran
ris tee
⇒ “6.4 Repairing
au
tho clutch housing”, page 82 or
ac
ss
6.1 Assembly overview - gearbox housing
ce
le
un
pt
an
d
itte
⇒ “6.1.1 Assembly overview - gearbox housing, gearboxes man‐
y li
erm
ab
ufactured up to 06.2012”, page 76
ility
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⇒ “6.1.2 Assembly overview - gearbox housing, gearboxes man‐
is n
h re
ufactured as of 06.2012”, page 78
ole,
spec
6.1.1 Assembly overview - gearbox housing, gearboxes manufactured up to
t to the co
06.2012
rrectne
1 - Guide plate
❑ Installation position: in‐
ss o
sert lug in hole for seal‐
cial p
f i
ing cover
nform
mer
2 - Bolt atio
om
❑ For securing guide plate

n
c
i
or
to gearbox housing
thi
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sd
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❑ Moisten threads of bolts

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pr
cum
with locking fluid ⇒

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❑ 10 Nm yri
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3 - Cap
agen
Prote AG.
❑ Drive out with a drift

working from inside of
gearbox housing after
track has been removed
❑ Drive in as far as stop
with a drift of
approx. 9 mm in diame‐
ter
4 - Bolt
❑ For securing reverse
gear wheel shaft
⇒ page 119
5 - Seal
6 - Dowel sleeves
❑ Insert in gearbox hous‐
ing
7 - Reverse gear wheel
❑ Note installation posi‐
tion ⇒ page 119
8 - Needle bearing
❑ For reverse gear

9 - Reverse gear axle

10 - Roller bearing
❑ For layshaft.
❑ Installation position: larger diameter of plastic cage must face layshaft
11 - Sleeve
❑ For layshaft roller bearing
❑ Pressing in ⇒ page 82 .
12 - Retaining ring
13 - Ball bearing
❑ Pressing out ⇒ page 82 .
AG. Volkswagen AG d
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es, in part or in w
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ion
c
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or
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ate
do
priv
cum
for
en
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t.
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Cop py
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Prote AG.
6. Gearbox housing, clutch housing 77

AG. Volkswagen
6.1.2 Assembly overviewVol
ksw
agen - gearbox A
housing,
G do
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ot g gearboxes manufactured as of
06.2012 rise by ua
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s
1 - Bolt
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❑ For guide element to
an
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gearbox housing
erm
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ility
❑ Moisten threads of bolts
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with locking fluid ⇒
, is n
h re
hole
spec
logue (ETKA)
es, in part or in w
❑ 10 Nm
t to the co
2 - Guide element
rrectness of i
3 - Pin
l purpos
4 - Bolt
gear wheel shaft
nf
ercia
or
m
m
atio
⇒ page 119
om
n in
or c
5 - Seal
thi
te
sd
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6 - Dowel sleeve
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❑ Insert in gearbox hous‐ C py
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ing
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7 - Reverse gear wheel Prote
cted AG.
agen

tion ⇒ page 119
⇒ page 120
8 - Needle bearing
❑ Moisten with gear oil
10 - Roller bearing
❑ For layshaft.
❑ Installation position: larger diameter of plastic cage must face layshaft
11 - Sleeve
❑ For layshaft roller bearing
12 - Retaining ring
13 - Ball bearing
❑ Pressing out ⇒ page 82 .

6.2 Assembly overview - clutch housing
1 - Ball bearing
❑ For input shaft
❑ Renew after removal agen
AG. Volkswagen AG d
oes
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❑ Pressing out byV
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⇒ page ri85 s .
ed
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❑ Heat s aubefore installing in‐ ra
c
puts shaft ⇒ page 84
ce
le
un
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❑ Pressing in
an
d
itte
⇒ page 85 .
y li
erm
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ility
2 - Retaining ring
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❑ For ball bearing in clutch
h re
ole,
housing
spec
3 - Input shaft
t to the co
❑ Press out of ball bearing
in clutch housing
⇒ page 84
rrectne
❑ Press into ball bearing in
clutch housing
ss
⇒ page 85
o
cial p
f inform
4 - Clutch housing
mer
atio
5 - Outer race, double deep
om
groove ball bearing

c
i
or
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e
❑ For layshaft.
t
sd
iva
o
r
❑ Pressing out
p
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⇒ page 85 .
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❑ Fitting position Cop py
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⇒ page 86
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❑ Pressing in by c lksw
cted agen
⇒ page 86 . Prote AG.
6 - Retaining ring
❑ For outer race, double
deep groove ball bear‐
ing
7 - Retaining ring
❑ For input shaft
❑ Remove before pressing out input shaft
6.3 Repairing gearbox housing

Removing and installing reverse gear wheel shaft with reverse
gear wheel ⇒ page 120


equipment required
AG. Volkswagen AG d
agen oes
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es, in part or in w
t to the co
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orm
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atio
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thi
te
sd
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Cop py
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rig ht
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by lksw
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Prote AG.
♦ Press tool - VW 408 A-

♦ Thrust plate - VW 510-
♦ Thrust plate - 3062-
♦ Wheel bearing tube - 3345-

♦ Retainer - VW 801-
♦ Hot-air blower -
V.A.G 1416-
AG. Volkswagen AG d
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♦ Puller - T50059-
ility
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t to the co
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mer
atio
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Pulling out sleeve -A- for

o
n
c
layshaft roller bearing

i
or
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te
sd
a
– Insert puller -
iv
o
pr
T50059- in recess in
um
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fo
en
sleeve -A-, and turn it

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by 90°. ht. Cop py
rig
rig ht
py by
co Vo
81
by lksw
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Prote AG.
6. Gearbox housing, clutch housing
– Pull sleeve out of

gearbox housing.
Installation position of sleeve -A- for layshaft roller bearing

• Recess -arrow 2- in sleeve and lug -arrow 1- must align.
Carefully pressing in sleeve -A- for layshaft roller bearing as far

stop agen
AG. Volkswagen AG d
oes
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ility
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hole
spec
es, in part or in w
t to the co
Pressing out ball bearing for output shaft
• Before pressing out, remove circlip ⇒ Item 12 (page 77) or
rrectness of i
⇒ Item 12 (page 78) .
l purpos
nform
mercia
at
om
ion
c
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or
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ate
do
priv
cum
for
en
ng
t.
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Pressing in output shaft ball bearing to stop
Co
Cop py
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Note Prote
cted AG.
agen
Before pressing in ball bearing, heat the bearing seat with hot air
blower -V.A.G 1416- , for example, to approx. 80°C.
– Install retaining ring ⇒ Item 12 (page 77) or

⇒ Item 12 (page 78) .
6.4 Repairing clutch housing


equipment required
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
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nl
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ab
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♦ Press tool - VW 407-

wit
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hole
spec
es, in part or in w
♦ Tube - VW 415 A-
t to the co
♦ Thrust plate - 3062-

♦ Tube - 3296-
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
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cum
for
en
ng
t.
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Cop py
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Prote AG.

♦ Wheel bearing tube -

3345-
♦ Hot-air blower -
V.A.G 1416- n AG. Volkswagen AG do
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spec
es, in part or in w
t to the co
♦ Inductive heater -
VAS 6414-
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
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Press input shaft out of yri
gh by
ht
ball bearing in clutch cop Vo
by lksw
housing.
cted agen
Prote AG.
• Before pressing out,

remove circlip
⇒ Item 7 (page 79) .
Heating inner bearing race of ball bearing for input shaft

– Heat the heating tool - T50060- with inductive heater - VAS
6414- , for example, to approx. 80°C, and insert it in inner
bearing race of ball bearing -A-. Do not heat the ball bearing
with a hot air blower.
– Then, press in input shaft ⇒ page 85 .

Pressing input shaft into ball bearing in clutch housing
Note
♦ The retaining ring -B- for the ball bearing is installed in the
clutch housing.
♦ Place the special tools -3296- and -VW 415 A- under the inner
bearing race of the ball bearing to prevent the new ball bearing
from being damaged.
– Press input shaft -A- into heated ball bearing.

– Install retaining ring ⇒ Item 7 (page 79) .
Pressing out ball bearing

wage
n Afor
G. Vinput
olkswashaft
gen AG
doe
ks s no
Vol t
• Before pressing
ed
by out, remove circlip ⇒ Item 2g(page
ua
ra 79) .
ris nte
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aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
Pressing in input shaft ball bearing to stop

rrectness of i
Note
l purpos
Before pressing in ball bearing, heat the bearing seat with hot air
nform
ercia
blower -V.A.G 1416- , for example, to approx. 80°C.

m
a
com
tio
– Install retaining ring ⇒ Item 2 (page 79) .

n in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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op py
Pressing out outer race for double deep groove ball bearing
. C rig
ht ht
rig by
py Vo
• Before pressing out, remove circlip ⇒ Item 6 (page 79) .
co lksw
by
cted agen
Prote AG.

Installation position of double deep groove ball bearing for lay‐

shaft
• The shoulder on the outer bearing race -arrow- must face to‐
wards stop in clutch housing.
Carefully pressing in outer bearing race of double deep groove

ball bearing for layshaft as far as stop
Note
♦ Before pressing in outer bearing race of double deep groove

ball bearing, heat the bearing seat with hot air blower -V.A.G
1416- , for example, to approx. 80°C.
♦ If the outer bearing race of double deep groove ball bearing
rests against the stop, do not apply any more force. Otherwise
the stop may break off the clutch housing.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
h
aut ra
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e
nl
pt
du
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ility
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, is n
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spec
es, in part or in w
t to the co
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nf
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orm
m
atio
om
n in
or c
thi
te
sd
iva
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cted
86
agen
Prote AG.
Rep. gr.34 - Controls, housing
AG. Volkswagen AG d
agen oes
olksw no
d by
V
Amarok t 2011
gu
ara ➤ , Amarok 2017 ➤
e nte
horis 6-speed manual gearbox 0C6e o - Edition 06.2019
aut ra
ss c
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7 Gear oil
un
pt
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itte
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ab
⇒ “7.1 Checking gear oil level”, page 87
ility
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⇒ “7.2 Draining and filling gear oil”, page 88
wit
is n
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ole,
7.1 Checking gear oil level
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
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i
or
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te
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Cop py
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♦ Clean container for 3.0 l gear oil, with scale yri
p by
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by c lksw
cted agen
Prote AG.
WARNING
Gear oils with different specifications are not allowed to be

mixed together.
Fill again if gearbox oil has expired.
Check
– Raise vehicle horizontally.
– Remove oil filler plug -1-.
– Use a piece of wire for checking, e.g. welding wire, with one
end bent over at 90° and cut off to 3 mm.
– Guide the bent end downwards into opening of oil filler plug.
– Remove wire and check whether bent end has oil on its end.
Note
Correct oil level is 2.5 mm below lower edge of filler hole. Precise
oil level can only be measured by draining completely.
7. Gear oil 87
AG. Volkswagen AG d
7.2 Draining and filling gear oil Volksw
agen oes
not
by gu
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Draining and filling orise nte
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– Raise vehicle horizontally. ss a c
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le
un
pt
an
d
itte
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– Unscrew oil drain plug -2- and collect gear oil in a clean con‐
rm
ab
tainer with scale.
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ility
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, is n
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WARNING
hole
spec
es, in part or in w
0.1 litre of oil remains in manual gearbox.
t to the co
rrectness of i
– Screw in oil drain plug and tighten it.
l purpos
– Top up gear oil in container to 1.4 l if necessary.

– Replenish with 1.4 l of gear oil.
nform
ercia
– Screw in oil filler plug -1- and tighten.

m
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ti
Observe the following for initial filling:
on in
r
te o
thi
– Raise vehicle horizontally.
s
iva
do
r

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cum
fo
en
ng
– Unscrew oil drain plug -2- and collect gear oil in a container.
t.
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Cop py
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– Screw in oil drain plug and tighten it. opyri
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– Replenish with 1 l of new gear oil.
lksw
cted agen
Prote AG.
– Screw in oil filler plug and tighten lightly.
– Move gearbox to neutral position and allow engine to run for
a few minutes.
– Switch off engine.
– Unscrew oil filler and drain plug and collect gear oil in a con‐
tainer.
– Screw in oil drain plug and tighten it.
– Replenish with 1.5 l of gear oil.
– Screw in oil filler plug and tighten it.
Specified torques
♦ ⇒ “5.2 Assembly overview - clutch housing and input shaft”,
page 52

35 – Gears, shafts
1 Input and output shafts
⇒ “1.1 Assembly overview - input shaft and output shaft”,
page 89
⇒ “1.2 Dismantling and assembling output shaft”, page 93
⇒ “1.3 Renewing input shaft seal”, page 104
⇒ “1.4 Renewing output shaft seal”, page 105
1.1 Assembly overview - input shaft and output shaft
Note
♦ When installing new gears, a new input shaft, or a new output shaft, refer to ⇒ Electronic parts catalogue
(ETKA) and technical data ⇒ page 6 .
♦ If the synchro-rings are renewed, the inner ring, intermediate ring and the synchro-ring for the respective
gear must be renewed together.
♦ Lubricate all bearings and synchro-rings with gear oil before installing.
♦ Heat inner races for needle bearing, synchro-hub and thrust washer ⇒ Item 33 (page 91) to maximum
100°C before installing. Wear protective gloves for this work.
Caution
Wrap a cloth around the locking collar for 3rd/4th gear and re‐
verse gear so that the balls and compression springs do not
spring away in an uncontrolled manner when the locking collar
is removed. en AG. V
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1. Input and output shafts 89

1 - Input shaft
❑ With gear wheel for 4th
gear
❑ Is also drive gear of the
constant mesh gear pair
⇒ page 79
2 - Roller bearing
❑ Installation position:
smaller diameter of
plastic cage -arrow-
faces input shaft
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7 - 3rd and 4th gear synchro-

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⇒ page 96
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⇒ page 102
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10 - Ball
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11 - Synchro-ring for 3rd gear
❑ Check for wear ⇒ page 98
12 - 3rd gear clutch body
13 - Synchromeshed gear for 3rd gear
14 - Needle bearing
❑ For 3rd gear
15 - Retaining ring
❑ For inner bearing race of roller bearing
90 Rep. gr.35 - Gears, shafts

16 - Inner race
❑ For roller bearing
❑ For removing, heat inner bearing race with a welding torch, for example
❑ Pressing on ⇒ page 104
17 - Output shaft
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23 - Synchro-ring for 2nd gear
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❑ Setting on synchro-hub ⇒ page 99

27 - Synchro-ring for 1st gear
28 - Intermediate ring for 1st gear
29 - Inner ring for 1st gear
❑ Renew if scored
30 - Needle bearing inner race
❑ For 1st gear synchromeshed gear
31 - Needle bearing
❑ For 1st gear
32 - Synchromeshed gear, 1st gear
33 - Thrust washer
❑ For 1st gear synchromeshed gear and reverse gear synchromeshed gear

❑ Pressing off ⇒ page 96
❑ For synchromeshed gear for reverse gear
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1.2 Dismantling and assembling output shaft

equipment required
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♦ Press tool - VW 408 A-
♦ Tube - VW 415 A-

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♦ Drift sleeve - 40 - 20-
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♦ Tube - 3146-
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♦ -3- Splitter - VAS 251 411- (Kukko 17-2)
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♦ Feeler gauge
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Dismantling output shaft

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– Carefully pull locking collar for 3rd and 4th gears off synchro-
hub. In the process, remove locking pieces, compression
springs and balls (3 of each).

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Pressing off synchro-hub for 3rd and 4th gears with 3rd gear syn‐
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– Flip output shaft -A-, and insert it in support with teeth of
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– Shift locking collar for 1st and 2nd gear to 2nd gear.
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Press off synchromeshed gears for 1st gear and reverse gear with
clutch body, thrust washer and needle bearing inner race for re‐
verse gear.
– Remove needle bearing and synchro-rings for synchromesh‐
ed gear of 1st gear.

Press off synchromeshed gear for 2nd gear with needle bearing
inner race and locking collar/synchro-hub for 1st and 2nd gear.
A - Splitter - VAS 251 411- (Kukko 17-2)
• Fit splitter -A- underneath constant mesh teeth -arrows- of
synchromeshed gear for 2nd gear.
• Do not fit splitter -A- at thrust washer ⇒ Item 18 (page 91) .
• After pressing off, make sure that the thrust washer
⇒ Item 18 (page 91) rests completely against the teeth of the
output shaft.
– Remove needle bearing for 2nd gear synchromeshed gear.
Assembling output shaft
Note
♦ Lubricate all needle bearings and synchro-rings with gear oil

before installing.
♦ Always press on inner races
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– Check inner friction surface of synchro-ring for grooves or

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– Moisten synchro-rings with gear oil before installing.

– Fit inner bearing race, intermediate ring and synchro-ring onto
rrectne
synchromeshed gear, and press them on.

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– Then measure gap -a- with a feeler gauge .

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♦ If components are not renewed, ensure that they are matched

with their original gears.

Checking synchro-rings for reverse gear and 3rd/4th gear for

wear
– Press synchro-ring onto cone of synchromeshed gear and
measure gap -a- using feeler gauge .
Gap -a- Wear limit
3rd and 4th gears 0.5 mm
Reverse gear 0.5 mm
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Installation position of synchro-rings for 2nd gear
Note

♦ The components might differ slightly from those shown in the
illustration.
– Set inner ring -2- on synchromeshed gear -1-.

– Set intermediate ring -3- in place.
• Lugs -A- must be inserted in recesses -B-.
– Fit synchro-ring -4-.
• Guide lugs -C- through notches -D-.
– Moisten needle bearing for 2nd gear with gear oil.
– Fit synchromeshed gear for 2nd gear together with needle
bearing and synchro-rings onto output shaft.
Heat synchro-hub for 1st and 2nd gear to about 100°C and press
on carefully
WARNING
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• When pressing on,
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Fitting locking collar for 1st and 2nd gear -A-

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• The recesses for the thrust pieces -C- in synchro-hub -B- and
locking collar -arrow- must align.
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Heating needle bearing inner race for 1st gear synchromeshed

gear -A- to about 100°C, and pressing it on
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Installation position of synchro-rings for u1st
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– Fit synchro-ring -2- in locking collar and synchro-hub for 1st
and 2nd gears -1-.
rrectness of i
• Lugs -B- must be inserted in notches -A-.
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– Set intermediate ring -3- in place.

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gear (will be set on later).

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Note
The 1st gear synchromeshed gear must be positioned below the

shoulder -arrow- for seating the thrust washer ⇒ page 101 .

Heat thrust washer -A- to about 100°C and press on to stop
WARNING
Note
Check synchromeshed gears for 1st and 2nd gears for slight axial
play of at least 0.10 mm or ease of movement.
Heating needle bearing inner race -A- of synchromeshed gear for

reverse gear to about 100°C, and pressing it on
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Moistenhorneedle bearing for reverse gear with gearnoil. tee
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– Fit synchromeshed
ss gear for reverse gear together with needle
bearing onto output shaft.
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Installing locking collar and thrust pieces for reverse gear

• The recesses for the thrust pieces -arrows A- in synchromesh‐
ed gear for reverse gear -2- and locking collar -arrow- must
align.
– Push locking collar -1- towards synchromeshed gear for re‐
verse gear -2- as far as stop.
– Install thrust pieces -3- with new compression springs -4-.
• Always renew compression springs -4-.
• The compression spring must be inserted in the centring hole
of the synchromeshed gear for reverse gear -2-.
– Then install balls -5-.
– Then press down thrust pieces -3-, and hold them in place
-arrows A- while simultaneously shifting locking collar to neu‐
tral position.
– Fit synchro-ring for reverse gear.
Note
The lugs of the synchro-ring must engage in recesses in the syn‐

chromeshed gear for reverse gear.
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– Fit sleeve - T50056/2- into support - T50056/3- instead of

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– Flip output shaft, and insert it in support - T50056- with clutch

t to the co
body for reverse gear facing downwards.

– Moisten needle bearing of synchromeshed gear for 3rd gear
rrectness of i
with gear oil.

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– Fit synchromeshed gear for 3rd gear together with clutch body,
needle bearing and synchro-ring onto output shaft.
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Installation position of synchro-hub for 3rd and 4th gears

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The high collar -arrow 1- and the marking -arrow 2- must face
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Heat synchro-hub for 3rd and 4th gears to about 100°C and press
on
WARNING
• When pressing on, the yokes of the synchro-ring -arrow- and

the recesses in the synchro-hub must align.
Note
Then, check synchromeshed gear for 3rd gear for axial play.
– Insert retaining ring ⇒ Item 5 (page 90) in circumferential

groove in output shaft.
Installing locking collar and thrust pieces for 3rd and 4th gear
• The recesses for the thrust pieces -arrows nA- in. Vsynchro-hub
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• The compression springs must be inserted in the centring hole
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The illustration shows the locking collar and synchromeshed gear

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for reverse gear. The assembly of the thrust pieces and locking
collar for 3rd and 4th gear is identical.
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Heat inner race for needle bearings to 100°C and press on.
WARNING
Install retaining ring ⇒ Item 15 (page 90) .
Note
Before installing the set of shafts, fit synchro-ring and clutch body
for 4th gear onto output shaft ⇒ page 68 .
1.3 Renewing input shaft seal

♦ Puller - T10055-
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♦ Sheet metal screw, about 4 mm in diameter

Removing
nform
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– Remove gearbox ⇒ page 38 .

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– Remove clutch release mechanism ⇒ page 12 .

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Rep. gr.35 - Gears, shafts
AG.
– To pull out seal, screw sheet metal screw of about 4 mm di‐

ameter -A- into seal.
Note
♦ Do not screw in sheet metal screw too far to avoid damaging

bearing behind it. agen
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♦ The input shaft seal can also be removed using extractor tool
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Installing
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– Lightly oil outer circumference of seal for input shaft, and half-
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spec
fill space between sealing lips -arrow- with grease .
es, in part or in w
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– Drive in new seal of input shaft to stop on tool using press tool
iv
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- T50038- .
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– Install clutch release mechanism ⇒ page 12 .
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– Install gearbox ⇒ page 43 . gh ht
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– Check gear oil level ⇒ page 87 . Prote
cted AG.
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Specified torques
♦ ⇒ “1.2 Assembly overview - clutch release mechanism”, page
12
1.4 Renewing output shaft seal


equipment required
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♦ Counter-hold tool - T10172-

ss o
♦ Removal tool - VW 681-

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♦ Two-arm puller - VAS 251 003- (Kukko 20-2) -1-

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Removing
– Remove propshaft flange ⇒ page 57 .
– Remove transfer box ⇒ Rep. gr. 39 ; Transfer box; Removing
– Remove adapter shaft for transfer box ⇒ page 59 .
– Using oil seal extractor lever - VW 681- , carefully lever out
seal of output shaft.
Installing
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– Lightly oil outer circumference of new seal for output shaft, and
nl
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half-fill space between sealing lips with sealing grease .

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– Drive in new seal of output shaft to stop on tool using press

tool - T50068- .
– Install propshaft flange ⇒ page 57 .
– Install adapter shaft for transfer box ⇒ page 59 .
– Check gear oil level ⇒apage
gen AG87 .
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Specified torques
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♦ ⇒ “5.3 Assembly
au
tho overview - gearbox housing, layshaft, eoutput
or
ac
shaft and
ss selector unit”, page 53
ce
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nl
♦ ⇒ Rep. gr. 39 ; Propshaft; Assembly overview - propshaft pt

du
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♦ ⇒ Rep. gr. 39 ; Transfer box; Assembly overview - transfer
erm
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2 Layshaft
⇒ “2.1 Assembly overview - layshaft”, page 109
⇒ “2.2 Dismantling and assembling layshaft”, page 112
2.1 Assembly overview - layshaft
Note
♦ When installing new gears or a new layshaft, refer to ⇒ Electronic parts catalogue (ETKA) .
♦ Lubricate all bearings and esynchro-rings
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AG gear oil before installing. ag does
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♦ Wearing protective
by gloves, heat inner bearing race gfor
ua needle bearing, inner bearing race for double deep
ot n
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groove ball bearing
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and synchro-hub for 5th and 6th gear
ran to approx. 100°C before installing.
te
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ut
♦ Make sure
ss that the splines of the synchro-hub and the layshaft
a ra
c mesh properly when installing.
ce
le
♦ Wearing protective gloves, heat constant mesh gear and 6th gear synchromeshed gear to maximum 150°
un
pt
an
d
C before pressing on.

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Caution
h re
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spec
Wrap a cloth around the locking collar for 5th/6th gear so that
es, in part or in w
the balls and compression springs do not spring away in an
t to the co
uncontrolled manner when the locking collar is removed.
rrectness of i
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2. Layshaft 109
1 - Inner race, double deep

groove ball bearing
❑ Remove inner bearing
race when double deep
groove ball bearing is
damaged ⇒ page 114
❑ Pressing on
⇒ page 118
2 - Retaining ring
❑ For constant mesh gear
❑ Redetermining thick‐
ness ⇒ page 117
olkswagen AG
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3 - Constant mesh gear olks
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❑ Pressing off ed
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⇒ page 114 tho eo
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high inside collar faces
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gear wheel for 3rd gear
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❑ Pressing on
erm
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⇒ page 117
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4 - Gear wheel for 3rd gear
h re
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spec
❑ Pressing off
⇒ page 115
t to the co
high inside collar faces
constant mesh gear
rrectne
❑ Pressing on
⇒ page 117
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5 - Synchromeshed gear for
inform
6th gear
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❑ Check for wear

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⇒ page 115
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8 - Needle bearing
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❑ For 6th gear
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❑ For 6th gear synchromeshed gear
10 - Synchro-hub for 5th and 6th gears
❑ Qty. 3
12 - Thrust piece
❑ Qty. 3
13 - Ball
❑ Qty. 3

oes 6-speed manual gearbox 0C6 - Edition 06.2019
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❑ Installing ⇒ ispage
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14 - Locking scollar
aut
for 5th and 6th gears ra
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17 - Synchromeshed gear, 5th gear
spec
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18 - Needle bearing
t to the co
❑ For 5th gear
19 - Thrust washer
rrectness of i
❑ For 5th gear synchromeshed gear
l purpos
20 - Layshaft
nform
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21 - Inner bearing race of roller bearing

m
❑ For layshaft.
at
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❑ For removing, heat inner bearing race with a welding torch, for example
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2. Layshaft 111
2.2 Dismantling and assembling layshaft

equipment required
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♦ Tube - VW 415 A-
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♦ Tube - VW 421-
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♦ Tube - VW 426-
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♦ Thrust piece - 32 - 111-
♦ Tube - 3296-
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♦ Thrust plate - T10084 A-

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♦ Feeler gauge
2. Layshaft 113
Dismantling layshaft
If double deep groove ball bearing for layshaft is damaged, inner
bearing race -arrow- must be removed.
– To do this, heat inner bearing race -arrow- with a welding torch
-1-, for example, and remove it from layshaft.
wage es n
Remove retaining ring -1- yV
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Pressing off constant mesh gear -A-
rrectness of i
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Note
nform
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♦ The press force can exceed 200 kN (20 t).

m
at
♦ When pressing off, ensure that the layshaft does not contact
om
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thrust plates .
n
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ate
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• If the press force is below 100 kN (10 t), renew the layshaft
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and the constant mesh gear.

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Pressing off gear wheel for 3rd gear with synchro-hub for 5th/
6th gear, needle bearing inner race for 6th gear and synchro‐
meshed gears for 5th and 6th gear
Note
The press force can exceed 200 kN (20 t).
• If the press force is below 100 kN (10 t), renew the layshaft
and the gear wheel for 3rd gear.
– Remove needle bearing and thrust washer for 5th gear.
Assembling layshaft
Note
♦ Lubricate all needle bearings and synchro-rings with gear oil

before installing.
♦ Always press on needle bearing inner race, synchro-hubs and
gear wheels as far as stop, so that the synchromeshed gears
have the prescribed axial play. agen
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If components are not renewed, ensure that they are matched
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Checking synchro-rings for 5th and 6th gear for wear

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– Press synchro-ring onto cone of synchromeshed gear and
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measure gap -a- using feeler gauge .
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Gap -a- Wear limit
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spec
5th and 6th gear 0.5 mm
es, in part or in w
t to the co
– Fit thrust washer for 5th gear.
– Moisten needle bearing for 5th gear with gear oil.
rrectness of i
– Fit synchromeshed gear for 5th gear together with needle
bearing, clutch body and synchro-rings onto layshaft.
l purpos
Heat synchro-hub for 5th and 6th gear to about 100°C and press
nform
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on.
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WARNING
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• When pressing on, the lugs of the synchro-rings and the re‐ t. C rig
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cesses in the synchro-hub -A- must align -arrow-. pyri by
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2. Layshaft 115
Installing locking collar and thrust pieces for 5th and 6th gear
• The recesses for the thrust pieces -arrows A- in synchro-hub
-2- and locking collar -arrow B- must align.
– Push locking collar -1- towards synchromeshed gear for
3rd gear -2- as far as stop.
• The compression springs must be inserted in the centring hole
of the synchro-hub -2-.
tral position.
Note
The illustration shows the locking collar and synchromeshed gear

for reverse gear. The setup of the thrust pieces and locking collar
for 5th and 6th gears is identical.
Heating needle bearing inner race -A- for synchromeshed gear of

6th gear to about 100°C, and pressing it on
WARNING agen
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Wear protective gloves. orised
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– Moisten needle bearing for 6th gear with gear oil.

un
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– Fit synchromeshed gear for 6th gear together with needle
rm
bearing, clutch body and synchro-ring onto layshaft. ab

pe
ility
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hole
Note
spec
es, in part or in w
t to the co
The synchromeshed gear for 6th gear must be positioned below

the shoulder for seating the gear wheel for 3rd gear.
rrectness of i
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Heat gear wheel for 3rd gear to 150°C and press on as far as stop
Installation position: high inside collar faces constant mesh gear.
WARNING
– Press on gear wheel -A- quickly so that heat is not immediately

transferred to layshaft.
Note
♦ When pressing on, hold synchro-assembly with synchromesh‐

ed gears for 5th and 6th gear -B- together.
♦ Then check synchromeshed gears for 5th ande6th gear for ax‐
n AG. Volkswagen AG
ial clearance. ksw
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Heating constant mesh gear to maximum
au
t
150°C and pressing on ra
c
ss
Installation position: high inside collar faces gear wheel for 3rd
ce
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nl
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gear
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WARNING
wit
, is n
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hole
spec
es, in part or in w
t to the co
– Press on gear wheel -A- quickly so that heat is not immediately
transferred to layshaft.
rrectness of i
l purpos
nf
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orm
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Determining thickness of retaining ring

o
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• Constant mesh gear is pressed on as far as stop.

en
ng
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– Install the thinnest retaining ring -B-, and measure gap be‐ t. C rig
gh ht
tween retaining ring and gearwheel with a feeler gauge. yri
p by
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by c lksw
cted
– Determine retaining ring with appropriate thickness, and insert
agen
Prote AG.
it; for part number refer to ⇒ Electronic parts catalogue (ET‐
KA) .
2. Layshaft 117
Heating inner race -A- of double deep groove ball bearing to about
100°C and pressing on
WARNING
Heating inner bearing race -1- for roller bearing to about 100°C,
and pressing it on
WARNING
Wear protective gloves. AG. Volkswagen AG d

agen oes
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rrectness of i
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3 Reverse shaft
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⇒ “3.1 Assembly overview - reverse shaft”, page 119
Vol
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⇒ “3.2 Removing and installing reverse shaft”,
or
ise page 120 nte
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3.1 Assembly overviewss - reverse shaft c
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pt
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1 - Gearbox housing
erm
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2 - Bolt
wit
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gear wheel shaft
spec
es, in part or in w
❑ 23 Nm
t to the co
3 - Seal
rrectness of i
4 - Reverse gear wheel
l purpos

tion ⇒ page 119
nform
ercia

m
⇒ page 120
at
om
ion
c
5 - Needle bearing
in t
or
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❑ Moisten with gear oil

at
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❑ Can be removed and in‐
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Reverse gear installation position

The shoulder -arrow- on the reverse gear wheel must face up‐
wards towards clutch housing.
3. Reverse shaft 119

3.2 Removing and installing reverse shaft

AG. Volkswagen AG d
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Removing
h re
ole,
spec
– Unscrew securing bolt -1- for reverse gear wheel shaft -2-.
t to the co
– Pull reverse gear wheel shaft upwards out of gearbox housing.
– Remove reverse gear wheel -3- and needle bearing.
rrectne
Installing
Install in reverse order of removal. The following should be ob‐
ss
served:
o
cial p
f inform
– Renew seal ⇒ Item 3 (page 119) on securing bolt.
mer
atio
Specified torques
om
n
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i
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n
♦ ⇒ “3.1 Assembly overview - reverse shaft”, page 119
thi
te
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Prote AG.

D4B8026D002-6-Speed Manual Gearbox 0C6

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D4B8026D002-6-Speed Manual Gearbox 0C6

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Service Department. Technical Information

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Copyright © 2019 Volkswagen AG, Wolfsburg D4B8026D002

1.5 Removing and installing clutch master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.6 Bleeding clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.2 Assembly overview - gear knob and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

1.4 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1.5 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

1.6 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1.7 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

1.8 Dismantling and assembling selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3.1 Assembly overview - assembly mountings, version A . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

5.6 Removing and installing propshaft flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

3.2 Removing and installing reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

⇒ “1.1 Safety measures when working on vehicles with a start/

stop system”, page 1

struments during a road test”, page 1

Observe the following when working on vehicles with a start/stop

Injury hazard as a result of automatic engine start in vehicles

with start/stop system.

ble by an indication in the dash panel insert) the engine

1.2 Safety precautions when using testers

Risk of accident due to distraction and inadequate securing of

2.1 Gearbox identification

Additional data depend on manufacture.

The manual gearbox code is also included on the vehicle data

2 Rep. gr.00 - Technical data

3.1 General repair instructions

♦ When exchanging manual gearbox, check oil level

lease bearing with hydraulic actuation ⇒ page 12 .

en bolts alternately and diagonally and in several gradual

as well as the friction surface of flywheel with a cloth to reduce

the smell of burnt linings.

4 Rep. gr.00 - Technical data

3.2 Gaskets and seals

♦ Following installation, check gear oil level ⇒ page 87 .

♦ Do not cant especially delicate parts, such as clutch pressure

plates. Loosen and tighten bolts and nuts in stages in a diag‐

♦ Always renew self-locking bolts and nuts.

Manual gearbox 6-speed manual gearbox 0C6, rear-wheel drive

6 Rep. gr.00 - Technical data

Manual gearbox 6-speed manual gearbox 0C6, rear-wheel drive

Glean following data from ⇒ Electronic parts catalogue (ETKA) :

Allocation Model Amarok 2011 ► Amarok 2011 ► Amarok 2011 ►

2.0 l - 132 kW turbo diesel

Gear ratios 1st gear 43 : 12 = 3.583 43 : 12 = 3.583 43 : 12 = 3.583

2nd gear 34 : 18 = 1.889 34 : 18 = 1.889 34 : 18 = 1.889

3rd gear 39 : 35 = 1.114 39 : 35 = 1.114 39 : 35 = 1.114

4th gear 1 : 1 = 1.000 1 : 1 = 1.000 1 : 1 = 1.000

Glean following data from ⇒ Electronic parts catalogue (ETKA) :

4.2.2 Allocation gearbox - engine, all-wheel drive

Manual gearbox 6-speed manual gearbox 0C6, all-wheel drive

Glean following data from ⇒ Electronic parts catalogue (ETKA) :

♦ Specification for gear oil

♦ Allocation of front and rear final drives according to engine

Manual gearbox 6-speed manual gearbox 0C6, all-wheel drive

8 Rep. gr.00 - Technical data

♦ Allocation of front and rear final drives according to engine

⇒ “1.3 Removing and installing over-centre spring”, page 12

⇒ “1.4 Removing and installing mounting bracket”, page 13

⇒ “1.5 Removing and installing clutch master cylinder”,