7-Speed Dual Clutch Gearbox 0AM

Service

Workshop Manual

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Service Department. Technical Information

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34 - Controls, housing 35 - Gears, shafts

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30 - Clutch

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00 - Technical data


Repair Group

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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 © 2010 Volkswagen AG, Wolfsburg

MEX5R008520

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010

Contents 00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 3 4 4.1 4.2 4.3 4.4

1

Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Code, engine allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Working with vehicle diagnostic testers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 2 3 4 4 4 6 6

30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

1 1.1 1.2 1.3

Removing and installing the dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting position of engagement bearings “K 1 and K 2” . . . . . . . . . . . . . . . . . . . . . . . . Installing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 8 12 22

34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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4.3 4.4 4.5 4.6 4.7 5


2.5 2.6 2.7 2.8 2.9 3 3.1 3.2 3.3 3.4 3.5 3.6 4 4.1 4.2

Renewing gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Overview - selector mechanism in vehicles up to 02.2009 . . . . . . . . . . . . . . . . . . . . . . . . 33 Removing and installing selector lever cable - vehicles up to 02.2009 . . . . . . . . . . . . . . . . 34 Overview of selector mechanism - vehicles from 03.2009 onwards . . . . . . . . . . . . . . . . . . 41 Removing and installing selector mechanism with selector lever and selector lever cable vehicles from 03.2009 onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 AG. Volkswagen . G Checking selector lever cable . .do.e.s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 ag.e.n . . . . . . . . . . A ksw no l o V ycable Adjusting selector lever . . . . . . . . . . . . . . . . . . . .t .gu.a.r . . . . . . . . . . . . . . . . . . . . . . . . . 43 b d an e te ris Emergency release ho of selector lever . . . . . . . . . . . . . . . . . . . .e o. . . . . . . . . . . . . . . . . . . . . . 46 t u a Removing andssinstalling selector lever handle . . . . . . . . . . . . . r.ac. . . . . . . . . . . . . . . . . . . . 46 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Mechatronic unit for dual clutch gearbox J743 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Safety note on mechatronic unit for dual clutch gearbox J743 . . . . . . . . . . . . . . . . . . . . . . 50 Overview - mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Removing mechatronic unit for dual clutch gearbox J743 with gearbox installed . . . . . . . . 52 Moving mechatronic unit for dual clutch gearbox J743 into “removal position” by hand . . 62 Installing mechatronic unit for dual clutch gearbox J743 . . . . . . . . . . . . . . . . . . . . . . . . . . 65 View of selector forks with mechatronic unit removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Information about gearboxes with different output shafts . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Removing gearbox, vehicles with 1.4 l/90 kW TFSI engine and 1.4 l/118 kW TSI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Removing gearbox, vehicles with 1.6 l/75 kW MPI engine . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Removing gearbox - vehicles with 1.9 l/77 kW TDI PD engine . . . . . . . . . . . . . . . . . . . . . . 90 Removing gearbox - vehicles with 1.6 l/77 kW TDI CR engine . . . . . . . . . . . . . . . . . . . . . . 97 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Torque settings “Gearbox to engine” and notes on assembly mounting . . . . . . . . . . . . . . 107 Transporting gearbox and securing to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 ht rig py Co t.

1 2 2.1 2.2 2.3 2.4

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Currently, no repairs can be made to gears and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 agen lksw Vo by

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39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 AG.

1

Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Contents

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Renewing oil seal for right stub shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing oil seal for left stub shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing seal for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Contents

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1.1 1.2 1.3 1.4

114 116 118 120


00 –

Technical data

1

Gearbox identification

KHN - Gearbox code letters ⇒ page 2 01.06.06 - Production date: 1 June 2006 14 - Factory code 14 15 - Time

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0026 - Serial number

1. Gearbox identification

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2

Code, engine allocation Allocation: gearbox codes for petrol engines KHN, LKG, LKM 1.4 l/90 kW TSFI

KUT, LPL 1.4 l/118 kW TSI

LSU 1.6 l/75 kW MPI

Allocation: gearbox codes for diesel engines KHM, LKL, LKF LQN, LST 1.9 l/77 kW TDI PD 1.6 l/77 kW TDI CR

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Rep. Gr.00 - Technical data

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ . Volkswagen AG - Edition 07.2010 7-speed dual aclutch gen AG gearbox 0AM do

Capacities

Mechatronic unit for dual clutch gearbox -J743-

1.7 l gear oil -G 052 171-

1 l central hydraulic oil and power steering oil -G 004 000-


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Further information in the part number designates the container size.

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3. Capacities

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4

General repair notes

4.1

Tools

Uncertainty often occurs with smaller bolts having low tightening forces. Torque wrench 2...10 Nm -V.A.G 1783- can be used with these bolts.

4.2

Gearbox

The gearbox has a hole in the housing.

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– Make sure no small parts drop into this hole during installation work.

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– Cover the hole with a cloth before installation work. Make sure that no dirt can enter an “open” gearbox. ♦ If gearbox covers have been unbolted or gearbox has no fluid, do not run engine. Do not tow vehicle. ♦ First thoroughly clean connecting points and surrounding areas and then loosen bolts. ♦ During installation, ensure that the dowel sleeves between the engine and gearbox are correctly located. ♦ Place removed parts on a clean surface. Cover parts to pre‐ vent soiling. Use plastic sheeting and paper. Use lint-free cloths only! ♦ Install only clean parts; do not remove Genuine parts from packaging until immediately before installing. ♦ If repair work cannot be performed immediately, cover opened parts carefully.

4. General repair notes

5

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Torque setting: 8 Nm



The cover prevents dirt getting in.


The “0AM” gearbox has two oil circuits. One oil fill is for gears, shafts and differential. A 2nd oil fill is for mechatronic unit for dual clutch gearbox -J743- . agen lksw Vo by

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Both oils are Genuine parts ⇒ page 3 . Do not mix “additives” in oil.

Oil which has been drained out cannot be added again. Caution

Use caution when handling oil. Dispose of used oil properly. One drop of oil will contaminate 600 litres of water.

4.4 •

Working with vehicle diagnostic testers

Only work with vehicle diagnostic testers from Volkswagen.

♦ Vehicle diagnosis and service information system -VAS 5052 A♦ Vehicle diagnosis, testing and information system -VAS 5051B♦ Vehicle diagnostic tester -VAS 5053Various functions are available in the operating modes guided functions and guided fault finding . The 3 most important functions are: ♦ Adapting installation information ♦ Reading measured values for mandatory reporting ♦ Initiating basic adjustment

4.4.1

Adapting installation information

The mechatronic unit detects other control units in the vehicle by means of signals on the data bus. Pressing the Adapt installation information lock button instructs the mechatronic unit to forget all communication partners.

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You cannot “generate” any faults using this function. Please al‐ ways perform the Adapt installation information function after the following activities: ♦ After a selector lever has been installed. ♦ After another control unit has been installed, e.g. engine, ABS or gateway. ♦ After work on the steering wheel paddle.

4.4.2

Reading measured values for mandato‐ ry reporting

You must read these measured values before contacting your Technical Service Center or your importer.

Initiating basic adjustment

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– Press the button DSG Mechatronic -J743- performing basic measurement only:

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This teaches important settings into the mechatronic unit. Even important adjustments are taught in again, or reset to program‐ med points. These include, for example, the synchronisation points and “reference points” for the engaging lever and gear ac‐ tuator.

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4.4.3


Save the measured values in the diagnosis log so that all neces‐ sary gearbox data will be available for fault analysis.

♦ if you are prompted to do so in “guided fault finding” ♦ after you have processed a fault entry ♦ after you have installed another gearbox ♦ after you have installed a clutch ♦ or after you have installed a mechatronic unit

4. General repair notes

7


30 –

Clutch

1

Removing and installing the dual clutch

Brief description The clutch is installed “upwards” with the gearbox removed. The mechatronic unit remains on the gearbox. If one new clutch is installed, the positions of the engagement bearings for “K 1” and “K 2” must be found and set. Then the clutch is pressed onto the input shaft. When installing a clutch, “most” mechanics push the clutch onto the input shaft up to the stop. This is not the optimum position for the clutch! For this reason, pull the clutch slightly “upwards” against the re‐ taining ring after it has been installed. olkswagen AG en AG. V

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The clutch is self-adjusting. Shocks can have an effect on this adjusting device. Therefore, please do not drop the clutch. Do not left the clutch drop into the gearbox either when installing the clutch. Even if the mechatronic unit has been removed, “pulling out” the assembly lever -T10407- under the engaging levers can have a negative effect on the adjusting device. Transporting gearbox and securing to assembly stand ⇒ page 111 . Remove dual clutch ⇒ page 8 . Adjust the position of the engagement bearings “K 1 and K 2” ⇒ page 12 . Install dual clutch ⇒ page 22 .

Removing dual clutch r fo ng

Special tools and workshop equipment required

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Rep. Gr.30 - Clutch

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♦ Hook -3438-

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♦ Assembly tool -T10356-

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♦ Puller -T10373-




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♦ Support device -T10323-

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♦ Thrust piece -T10376-

– Remove gearbox ⇒ page 73 .

1. Removing and installing the dual clutch

9

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Pull off both breather caps -arrows- and close using suitable plugs to achieve an oil-tight seal.

Turn gearbox with clutch upwards. For information about how to transport the gearbox securely and attach it to the assembly stand ⇒ page 111 .



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– Remove retaining ring of hub -arrow-.


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Rep. Gr.30 - Clutch

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– Remove hub with hook -3438- and a screwdriver.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Remove retaining ring of clutch -arrow-.

Note ♦ It is possible that the retaining ring is seated very tightly. The

cause may be that the clutch is pressing so hard against the retaining ring that the ring is stuck.

♦ If you cannot get the ring out of the groove, press the clutch

down slightly. Never strike the clutch or shaft with a hammer! Set up the tools that are shown in this illustration.

♦ Support bracket -T10323- fits on all 0AM gearboxes. ♦ Make sure that you place support bracket -T10323- in parallel

to the gearbox flange.

♦ Secure engine support with bolts -A-, as required with nuts. ♦ Always renew retaining ring.

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– Remove clutch together with puller -T10373- .



– Pull off clutch.


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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Remove small engagement bearing. – Remove large engaging lever.

– Remove bolts and remove small engaging lever.

– Remove retainer for engaging lever.

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Install dual clutch ⇒ page 22 .


1.2


Adjusting ⇒ page 12 .


Before installing clutch, please refer to ⇒ page 12 er “clutch needs adjusting during assembly or not.”

Adjusting position of engagement bear‐ ings “K 1 and K 2”


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Rep. Gr.30 - Clutch

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♦ Gauge block -T10374-

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 ♦ Ruler -T40100-

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♦ Adhesive -AMV 195 KD1 01♦ Micrometer caliper


♦ Digital depth gauge e.g. -VAS 6594-


Position of engagement bearings must be set after clutch and its actuators have been renewed. ♦ Retainer also belongs to actuator.

There is no need to adjust anything if all the named parts have only been removed and reinstalled. Only use tools in perfect condition.

•

Contact surface of “gearbox on engine” must be free from “ir‐ regularities”. This guarantees straight edge makes good con‐ tact.

•

Mechatronic unit is installed.

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In the following procedure, you are first shown how to measure all necessary dimensions “on gearbox”, in order to determine what is the appropriate shim. Tolerances on gearbox and toler‐ ances in clutch determine thickness of shim.

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Position of engagement bearings is comparable with clutch play of a manual gearbox. In this 0AM dual clutch gearbox, there are tolerances in engagement system of gearbox and in gearbox it‐ self. There are also tolerances within the dual clutch. These tolerances must be considered separately when adjusting.

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Perform the following steps:


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Conditions:

First find a dimension “B”. This dimensions is required for both clutches “K 1” and “K 2”. Then find a dimension “A” for each clutch. The following 2 illus‐ trations show where to measure these dimensions.


13


Do not install small engagement bearing, do not insert any shim.

Rep. Gr.30 - Clutch

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– Install parts of clutch as far as large engaging lever ⇒ page 22 .

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Adjusting:

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Perform the following steps “in sequence” and precisely.


Note

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“K 2”

14


“K 1”

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Install retaining ring of outer input shaft -arrow-.

– Place a ruler -T40100- on its side on flange of clutch housing. It should lie sideways on shaft end. Note

Ruler -T40100- should remain in this position during subsequent measurements. Do not turn over, do not remove.

– “Zero” depth gauge.


– Measure distance from retaining ring. – Note down result and call it “B”. Example: “B” = 2.91 millimetres

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– Place digital depth gauge onto outer input shaft.




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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Measure dimension “B” again on opposite side. Note

Do not measure on ring joint. This could force ring away at that point and falsify measuring result. – Remove retaining ring again. This ring is not allowed to be installed again! – Calculate average of both measuring results. Example: Dimension “B” = B1+B22 = 2,91+3,02 = 2.96 This dimension “B” is needed in the following calculations. In the following sample calculations, “B” should be 2.96 mm. The dimension given for “B” is and example. The value for “B” may be different in another gearbox. AG. Volkswagen AG d oes not gu ara e nte is r o eo h measures, as Each measurement requires different preparatory ut ra a c well as a few calculations. Please comply with the following work‐ s s

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ing procedures.


Do not insert any shim!


Start by calculating shim for clutch “K 1”.

– Place gauge block -T10374- on “large” engagement bearing. – Press once onto gauge block -T10374- whilst turning.

– Place digital depth gauge “at top” onto outer input shaft.

AG.

Rep. Gr.30 - Clutch

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Ruler -T40100- is already “on its side” on gearbox flange ⇒ page 15 .

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In this way, it is possible to observe how the engagement bearing turns. This means gauge block -T10374- also “sits” correctly on bearing.



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– Measure distance from “shaft end” to gauge block -T10374- .

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AG.

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – To make sure this measurement is as accurate as possible, position digital depth gauge twice at opposite sides. This allows the value to be found even more accurately, because the inaccuracy caused by “tilting” on the engagement bearing is minimised. – Calculate average of both measurements onto gauge block T10374- . – Note down this value and call it “A1”. Example: Dimension “A1” = 2,61+2,812 = 2.71 Example: “A1” = 2.71 millimetres Next calculation: “A1” minus “B” plus height of gauge block -T10374- = Depth of engagement bearing of clutch 1. Height of gauge block -T10374- is always the same. It is: 51.81 mm. Sample calculation: 2.71 mm minus 2.96 mm plus 51.81 mm = 51.56 mm. You have now calculated value for how deep engagement bear‐ ing is actually seated inside gearbox. Depth of bearing in each gearbox should be 50.08 millimetres. Subtract nominal dimension “50.08 millimetres” from this actual value. This gives result for actual gap of clutch 1. – Continue the calculation: Calculated value (in example: 51.56 mm) minus nominal dimen‐ sion = gap of clutch. Sample calculation: . Volkswagen AG does not l o V gu y b ara d Now tolerances in dual clutch must be introduced into this calcu‐ nte ise r o eo lation. Procedure for this is very simple: h t u ra a c s s of “new” clutch. – Please read off value of clutch tolerance

n AG 51.56 mm minus “50.08 millimetres” = gap of clutch 1 =ks1.48 wage mm.



A value between minus 0.40 and plus 0.40 millimetres is provided with a new clutch.


– Make a note of this value.

Example 1: “- 0.40” is indicated on your clutch. The previous calculation for “K 1”: “your calculated” gap minus value of clutch 1 = 1.48 mm minus 0.40 = 1.08 mm.

Example 2: “+ 0.20” is indicated on your clutch. Then, the last calculation of “K 1” is as follows: 1.48 mm plus 0.20 = 1.68 mm. – Refer to table to find correct shim and install.

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AG.

Prote cted by


Rep. Gr.30 - Clutch

thi sd o cu m en

18

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Calculated shim thickness

Shim to be installed (in milli‐ metres)

– From the supplied shims, select the one that is required. WARNING

Later on, only insert this 1 shim. Not 2 shims.

– Continue setting for clutch “K 2”.

Do not insert any shim!

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– Only insert small bearing.

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Calculate shim for clutch “K 2”.

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With this, you have found “correct” shim for “K 1”. Please install this shim during subsequent clutch installation.



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from to 0.31 0.90 0.8 0.91 1.10 1.0 olkswagen AG en AG. V g d a o e w 1.11 s1.2 s k1.30 not Vol gu by 1.50 ara d 1.31 1.4 e nte ris o eo h t 1.51 au 1.70 1.6 ra c ss 1.71 1.90 1.8 1.91 2.10 2.0 2.11 2.30 2.2 2.31 2.50 2.4 2.51 2.70 2.6 2.71 3.30 2.8

AG.

Prote cted by

Small engagement bearing only fits in one position due to 4 grooves.


19



– Place gauge block -T10374- on small bearing “with large opening upwards”.

– Place digital depth gauge “at top” onto outer input shaft.

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Prote cted by

Rep. Gr.30 - Clutch

AG.

20

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– Measure distance from “shaft end” into gauge block -T10374- .

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– “Zero” depth gauge.




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– By “turning”, check whether small engagement bearing is in‐ stalled correctly and that grooves are seated correctly.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – To make sure this measurement is as accurate as possible, position digital depth gauge twice at opposite sides. This allows the value to be found even more accurately, because the inaccuracy caused by “tilting” on the engagement bearing is minimised. – Calculate average of both measurements onto gauge block T10374- . – Note down this value and call it “A2”. Example: Dimension “A2” = 2,50+2,542 = 2.52 Example: “A2” = 2.52 millimetres Next calculation: lkswag-T10374“A2” minus “B” plus height ofggauge block = Depth of en AG n AG. Vo does a e2. engagement bearing ofVoclutch not lksw gu a

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ran e Height of gauge oblock -T10374- is always the same. On inside, tee it ris h t or is: 36.20 mm.au a c

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Sample calculation: 2.52 mm minus 2.96 mm plus 36.20 mm = 35.76 mm. es, in part or in w l purpos hole ercia , is n m ot com

Depth of bearing in each gearbox should be 34.35 millimetres. Subtract nominal dimension “34.35 millimetres” from this actual value. This gives result for actual gap of clutch 2. – Continue the calculation: Calculated value (in example: 35.76 mm) minus nominal dimen‐ sion = gap of clutch. Sample calculation: 35.76 mm minus “34.35 millimetres” = gap of clutch 2 = 1.41mm.

– Please read off value of clutch tolerance of “new” clutch. A value between minus 0.40 and plus 0.40 millimetres is provided with a new clutch. ht rig py Co t.

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– Make a note of this value.

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Now tolerances in dual clutch must be introduced into this calcu‐ lation. Procedure for this is very simple:


You have now calculated value for how deep engagement bear‐ ing is actually seated inside gearbox.

Example 1: “- 0.40” is indicated on your clutch. AG.

The previous calculation for “K 2”: “your calculated” gap minus value of clutch 2 = 1.41 mm minus 0.40 = 1.01 mm. Example 2: “+ 0.20” is indicated on your clutch. Then, the last calculation of “K 2” is as follows: 1.41 mm plus 0.20 = 1.61 mm. – Refer to table to find correct shim.


21

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Calculated shim thickness

0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8

– From the supplied shims, select the one that is required.

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Prote cted by

Later on, only insert this 1 shim. Not 2 shims.

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WARNING

AG.

With this, you also have found “correct” shim for “K 2”. Please install this shim during subsequent clutch installation. This shim should be under small engagement bearing.

1.3

Installing dual clutch

Special tools and workshop equipment required ♦ Support device -T10323-

22

Rep. Gr.30 - Clutch

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to 0.90 1.10 1.30 1.50 1.70 1.90 2.10 2.30 2.50 2.70 3.30


from 0.31 0.91 1.11 1.31 1.51 1.71 1.91 2.11 2.31 2.51 2.71

Shim to be installed (in milli‐ metres)

, Jetta 2011 ➤


AG. Volkswagen AG d agen oes ksw not l o V gu y b ar d Golf Variant ➤ nte ise 2007 ➤ , Golf Variant 2010 ➤ , Jetta a2005 r o h t dual clutch gearbox 0AM - Edition 07.2010 e or 7-speed u ac a ss

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 ♦ Assembly tool -T10356-



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AG.


Caution

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♦ Adhesive -AMV 195 KD1 01-


♦ Thrust piece -T10376-


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♦ Puller -T10373-

Do not oil or grease anything! Before clutch is installed, position of engagement bearings “K 1 and K 2” must be set ⇒ page 12 .


23

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Insert plastic retainer of engaging lever and check for correct seating.

– Install small engaging lever with clip.


Only a few, “older gearboxes” do not have a clip. “New” clutches always have one clip. – Check engaging lever is properly seated.

– Screw on engaging lever with 2 new bolts. Torque setting: 8 Nm + 90° Note

Before continuing with assembly, check whether clutch needs to be adjusted.

Do not continue with the assembly before the clutch has been adjusted! Adjust positions of engagement bearings ⇒ page 12 .

24

Rep. Gr.30 - Clutch

AG.

Caution

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– Check both engaging levers are seated correctly.


This “larger” lever is for clutch “K 1”.

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– Insert 2nd, “larger” engaging lever.

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Mounting for engaging lever and entire mechanism of engage‐ ment bearing must be dry and free from oil or grease. If neces‐ sary, clean these components with a cloth.




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Sleeve with its retaining plate fits only in one position.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Insert small engagement bearing with measured shim. Shim should be under small engagement bearing. Therefore, in‐ sert shim first.

Small engagement bearing only fits in one position due to 4 grooves.




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– By “turning” bearing, check whether it is installed correctly and that grooves are seated correctly.


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If clutch has been replaced, shim should also be under bearing.

– Secure shim using 3 drops of glue -AMV 195 KD1 01- .

Large shim is for clutch “K 1”, small one for clutch “K 2”. – Turn back spindle of puller -T10373- .

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This prevents shim from slipping out of its seat when clutch is inserted.

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25

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AG.


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ olkswagen AG en AG. V 7-speed dual clutch gearbox 0AM - Edition doe wag07.2010 – Insert clutch.

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Note


– Turn spindle “back” first.

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– Use puller -T10373- to insert

s no t gu ara nte eo ra c

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The clutch is self-adjusting. Shocks can have an effect on this adjusting device. Therefore, please do not drop the clutch. Do not left the clutch drop into the gearbox either when installing the clutch. – Press clutch on onto stop. Support bracket -T10323- fits on all 0AM gearboxes. – Make sure that you place support bracket -T10323- in parallel to the gearbox flange. – Push clutch down via spindle.

Prote cted by

If you can insert retaining ring -arrow-, clutch is correctly pressed on to stop. – Insert new retaining ring -arrow-.

26

Rep. Gr.30 - Clutch

AG.

Installation position of retaining ring: Joint of retaining ring is “nar‐ rower at top”.

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Place a hand on clutch whilst pressing on. You will be able to feel a slight rattling. Rattling means the clutch is being pressed onto its press seat. In the same way, you can also “feel” the stop when the clutch has reached its seat.

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Note

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Secure engine support with bolts -A-, as required with nuts.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – To enable clutch to find its installation position already, turn clutch against puller -T10373- by hand. •

Now turn clutch by hand, without using a tool.

In this way, clutch slides against retaining ring. Do not use any other tool. Pressing on causes “clutch to locate at bottom” on input shaft. Clutch should only be pulled up far enough for it to contact re‐ taining ring.



Then insert hub.



Hub has a “large” tooth and therefore only fits in one position.

“Large” tooth has a mark on -engine end- -arrow-.

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27

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Insert retaining ring for hub -arrow-. Installation position: Joint of ring must point towards “hub” on clutch.



Engaging levers must remain “still” in their position whilst this is being done. They are not allowed to move up and down.

AG.

Prote cted by

Rep. Gr.30 - Clutch

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28

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If an engaging lever moves up and down, then shim is not properly seated.

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–

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d“small” engaging lever whilst Turn clutch by hand and observe ran ir se tee o turning. h t or u ac a ss

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Remove clutch again in this case ⇒ page 8 . – Look at shims -arrows- precisely. Shims must be correctly seated. They must not be damaged.


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After the gearbox has been installed, you must initiate a basic adjustment using the ⇒ Vehicle diagnosis, testing and information system VAS 5051 ⇒ page 7 .




– Remove plugs and put both breather caps -arrows- back on.

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•

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AG.


29



34 –

Controls, housing

1

Renewing gear oil

The gearbox is filled for life. Therefore, there is no need the oil level of this gearbox.



This explains why there is no oil level check.

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte to check ise r o eo h t u ra a c s s

In case of leaks on gearbox, find out what is the cause and rectify the faults. – Place drip tray under gearbox. Then drain all gear oil and fill with new oil. – Then install the drain plug again.


– Raise vehicle.

If the gearbox is installed, you must remove the battery and bat‐ tery tray to add oil.

AG.

Prote cted by

Rep. Gr.34 - Controls, housing

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30

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– Move selector lever to position “P” position.

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– Remove battery and battery tray -arrows- ⇒ Rep. Gr. 27 ; Battery; Removing and installing battery .

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Remove securing clip in -direction of arrow-. Securing clips for selector lever cable must always be renewed. – Remove Bowden cable from ball head.

– Use your hand to press lever to stop in direction of cable sup‐ port bracket.





– Note installation position of lever and remove it from selector shaft. – If you are unsure, refer to this illustration for guidance. – Unbolt cover.

Only leaking covers must be renewed. If the cover was not leak‐ ing, it does not need to be renewed.

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AG.

Prote cted by

Caution

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– Take care not to “spill” any. Gearbox must have precisely 1.7 litres of oil.

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– Pour 1.7 l of oil in through opening -arrow-.

Do not fill any more or any less oil. Malfunctions would result! – Clean sealing surface on gearbox and on cover.

1. Renewing gear oil

31



– Fit cover and lever again.

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Attach lever again in same position.


– If you are unsure, refer to this illustration for guidance.

– Therefore, when installing, always use a “new” securing clip. – Adjust selector lever cable ⇒ page 43 .

32


AG.

A securing clip which has been removed is not allowed to be in‐ stalled again. The clip will have lost its internal tension and so it might fall off.

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– Press selector lever cable back onto ball head and install new securing clip.


– Always renew bolt of lever.


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Grease oil seal in cover with sealing grease -G

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Note

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h 052 128 ut A1- . ra a c s s


2

Selector mechanism WARNING

Before working on vehicle with engine running, move selector lever into position “P” and apply handbrake.

2.1

Overview - selector mechanism in vehicles up to 02.2009

Selector mechanism from 03.2009 onwards ⇒ page 41 . 1 - Selector cover with handle ❑ Do not remove handle without reason. For emergency release, on‐ ly the cover needs to be unclipped ⇒ page 46 . ❑ Before removal of han‐ dle, pull lock button out past its pressure point. Secure locking button with a cable tie or appro‐ priate wire against being pressed in. This will pre‐ vent lock button from being accidentally pressed into the handle. ❑ Removing and installing selector lever handle ⇒ page 46

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2 - Selector mechanism with selector lever AG. Volkswagen AG d agen oes ❑ With selector lever lock ksw not l o gu yV solenoid -N110b ara d e nte is r eo ❑ Emergency releasetho u ra a ⇒ page 46 . c s s ❑ Brief instructions for re‐ moving and installing:

–

Remove Bowden cable from gearbox ⇒ page 34 .

–

If necessary, disconnect or remove parts of ex‐ haust system ⇒ Rep. Gr. 26 ; Removing and installing parts of exhaust system .

–

Remove heat shield beneath selector mechanism.

–

Adjust selector lever cable after installing ⇒ page 43 .

3 - Bolt with spring ❑ 3 Nm

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4 - Pin ❑ Removing ⇒ page 34

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Remove centre con‐ sole.


–

2. Selector mechanism

33

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AG.


olksw

agen AG n AG. V Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta does ➤ wage 2005 ➤ , Jetta 2011 not olks V gu 7-speed dual clutch gearbox 0AM - Edition y 07.2010 b a d

❑ Do not grease


7 - Selector housing ❑ With seal


6 - Nut ❑ 9 Nm ❑ Qty. 4


5 - Locking plate ❑ Always renew after removing

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e ris tho u a ss

8 - Selector lever cable ❑ Bowden cable is not greased ❑ Removing and installing ⇒ page 34 ❑ Checking ⇒ page 43 ❑ Adjusting ⇒ page 43

Prote cted by

Removing and installing selector lever cable - vehicles up to 02.2009 Note

Following installation, Bowden cable must be checked for ease of movement and be adjusted. Removing – Move selector lever to position “S” position.

34


AG.

2.2

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Torque setting , selector lever to selector shaft ⇒ page 30 .

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10 - Hexagon flange nut ❑ 8 Nm ❑ Qty. 4

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9 - Securing clip ❑ Always renew after removing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Remove securing clip in -direction of arrow-. Securing clips for selector lever cable must always be renewed. – Remove Bowden cable from ball head. – Raise vehicle. – To remove Bowden cable and/or selector mechanism, heat shield under selector mechanism and, if necessary, parts of exhaust system must now be removed ⇒ Rep. Gr. 26 ; Re‐ moving and installing parts of exhaust system .


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– Remove locking plate of cable support bracket. Always renew locking plate.



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– Remove -selector housing- beneath selector lever.


35

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AG.



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AG.



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36

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-Selector housing- is pushed forwards slightly on cable.





Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 To remove cable, securing tab must be pushed forwards -arrow 1-. – At same time, push -pin- up with a screwdriver -arrow 2-.


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– Please insert -screwdriver- from underneath whilst pushing securing tab forwards.

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37

AG.


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Clarification: ♦ -Arrow 1- Push tab forwards

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AG.

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– Remove selector lever cable. Remove selector housing from cable. Installing – Route selector lever cable without tension. Also insert into ca‐ ble support bracket on gearbox. Do not secure with securing clips yet. Do not clip in ball head.

38


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♦ -Arrow 2- Push pin up

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Ensure that selector lever cable is properly routed during in‐ AG. Volkswagen AG d agen oes stallation. w s n lk o yV

b ed If the sheet metal is bent downwards, it may cause noises. The ris o h cable will vibrate against the sheet metal. t u

sa




– Observe sheet metal.s Press it back up in the tunnel during installation.

ot g ua ran tee or ac

Loosen adjustment screw -arrow-.

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– Put selector housing onto cable.

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AG.

– Insert selector lever cable into selector mechanism. – Insert cable into bearing and insert pin from above, down‐ wards through eye. When you have checked freedom of movement of cable ⇒ page 43 , insert locking plate.

– Attach cable with new locking plate on cable support bracket of selector mechanism. 2. Selector mechanism

39


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AG.

40

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– Check cable ⇒ page 43 .

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– Remove selector housing, heat shield and exhaust system ⇒ Rep. Gr. 26 ; Removing and installing parts of exhaust sys‐ tem .




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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ dual clutch gearbox 0AM - Edition 07.2010 gen A AG. Volkswa7-speed G do es n ot g ua ran tee or ac

Overview of selector mechanism - vehicles from 03.2009 onwards ss

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AG.

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2 - Selector mechanism with selector lever and selector lev‐ er cable ❑ With selector lever lock solenoid -N110❑ Bowden cable must not be greased ❑ Removing and installing ⇒ page 42 ❑ Checking ⇒ page 43 ❑ Adjusting ⇒ page 43

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1 - Selector cover with handle ❑ Do not remove handle without reason. For emergency release, on‐ ly the cover needs to be unclipped ⇒ page 46 . ❑ Before removal of han‐ dle, pull lock button out past its pressure point. Secure locking button with a cable tie or appro‐ priate wire against being pressed in. This will pre‐ vent lock button from being accidentally pressed into the handle. ❑ Removing and installing selector lever handle ⇒ page 46

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2.3

n wage olks V by ed ris o th au


3 - Bolt ❑ 8 Nm 4 - Hexagon flange nut ❑ 8 Nm ❑ Qty. 4 5 - Selector housing 6 - Securing clip ❑ Always renew after removing


41


2.4

Removing and installing selector mech‐ anism with selector lever and selector lever cable - vehicles from 03.2009 on‐ wards

Perform the following steps: Selector mechanism and selector lever cable are not allowed to be separated from one another. Both are removed together. In the engine compartment, it may be necessary to provide instal‐ lation space. Often, it is necessary to remove air filter. In the interior, it may be necessary to remove centre console. Note ageease n AG d AG. Volkswfor Following installation, Bowden cable must abe genchecked oes ksw not l of movement and be adjusted. o g yV

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– Move selector lever to position “P” position. ss pe rm itte d

– Remove selector lever handle ⇒ page 46 .



– Remove centre console ⇒ Rep. Gr. 68 .

– Remove 4 bolts.

Torque setting: 8 Nm – Raise vehicle.


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AG.


– Remove securing clip in -direction of arrow-. Securing clips for selector lever cable must always be renewed. – Remove Bowden cable from ball head.

42


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To do so, remove parts of exhaust system if necessary ⇒ Rep. Gr. 26 ; Removing and installing parts of exhaust system .

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– Remove heat shield beneath selector mechanism. This makes subsequent removal of selector mechanism easier.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Remove selector mechanism. Install in reverse order of removal. – Before you put on ball head: check cable ⇒ page 43 . – Install all parts of exhaust system which were removed ⇒ Rep. Gr. 26 ; Removing and installing parts of exhaust system . – Install heat shield ⇒ Rep. Gr. 66 . – Adjust selector lever cable after installing ⇒ page 43 .

2.5

Checking selector lever cable

Brief description Selector lever cable must be removed from gearbox so that its freedom of movement can be checked. Put removed end down so it does not rub against anything. Then the selector lever must be moved and after that, the Bowden cable must be reattached to the gearbox. Then the selector lever cable must be adjusted ⇒ page 43 . Do not grease connections of cable! Checking – Move selector lever to position “P” position. – Remove cable from lever on gearbox. – Move selector lever repeatedly from “P” to “S” and back to “P”. •

Selector lever must move easily.

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Adjusting selector lever cable

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AG.



2.6


– Adjust cable ⇒ page 43 .


n AG. Volkswagen AG do es n wage s k l ot g o – Reinstall cable with “loosened” adjustment screw. yV ua b d ran ir se tee If you remove the securing clip, you must always install thao “new” or u ac a securing clip. ss

43

Prote cted by




The selector lever cable must always be adjusted whenever ♦ The selector lever cable has been removed from the gearbox. ♦ The engine and/or gearbox has been removed and installed. ♦ Parts of the assembly mounting have been removed and in‐ stalled. ♦ The cable itself or the selector mechanism has been removed and installed. ♦ The position of the engine and gearbox is shifted, for example to install it free of tension. Adjusting

– Move selector lever in vehicle to “P” position. Adjuster screw -arrow- must be “loosened”.

Prote cted by


AG.

44

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The gearbox lever must be pressed “completely to right side of vehicle” in the direction of selector lever cable support bracket.

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– Shift lever on gearbox to position “P”.




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♦ Torque wrench -V.A.G 1331-

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 This figure shows you the view of gearbox from “behind”. -P- in direction of cable support bracket.


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WARNING

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– Install Bowden cable with and new securing clip.

AG. Volkswagen AG d agen oes ksw not l o V gu y b loosened adjusting screw -arrowara d nte ise r o eo h t u ra a c s s



Be sure that the parking lock is engaged. – To do this, turn both front wheels simultaneously “under the car” in the same direction until the parking lock can be head to engage. •

The parking lock is engaged when both front wheels cannot be turned in the same direction at the same time.

– Gently push handle of selector lever forwards and backwards but under no circumstances must you shift out of “P”. In this way the inner cable of the Bowden cable finds it optimal position.

This completes the adjustment.

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– Tighten adjusting screw -arrow- to 13 Nm.

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45

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AG.

Prote cted by



2.7

Emergency release of selector lever

Do not remove handle. –


– Press yellow plastic part -arrow- from right to left. – Or press on the pin of the solenoid.

Vehicles from 03.2009 onwards

It is possible with all handles that lock button is pressed into han‐ dle. Do not install a handle with the locking button pressed in. – Before removal, pull lock button out past its pressure point. – Secure locking button with a cable tie or wire against being pressed in. – Unclip cover.

46


AG.

Removing and installing selector lever handle

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2.8

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– Press onto yellow plastic part -arrow-.



Vehicles up to 02.2009

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–

AG. Volkswagen AG d agen oes ksw not l o V gu ara Unclip selector cover and hold to side.ed by nte is r o eo h Depress brake pedal or set handbrake. ut ra a c s s

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Push sleeve upwards to release handle. – Lock the handle again after installing. To do this, press the sleeve under the handle back down.

– You only have to remove transport guard from “new” handles. The locking button is already in installation position. – Pull connector from cover. – Pull off handle upwards. – Lock the handle again after installing. Press the sleeve under the handle back down.

In vehicles with lock button at front on handle -arrow-


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Lock button -arrow- is not allowed to be pressed in when handle is being fitted and removed.


47

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AG.


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – However, should this happen, unclip handle trim upwards. – Press small lever for pull rod -arrow- back into groove before installing handle.

2.9

Checking selector mechanism

Faults which can be detected electrically can be determined with guided fault finding . In the case of mechanical faults, skill is required to localise and repair a faulty system or defective “part”. It must not be possible to start the engine in the selector lever positions “R”, “D” or “S”. When selector lever is shifted to position “N” at speeds above 5 km/h, solenoid for selector lever lock must not engage and block selector lever. Selector lever can be shifted into a driving range. When travelling at speeds below 5 km/h (almost stationary) and shifting into selector lever position “N”, solenoid for selector lever lock should only engage after about 1 second. Selector lever can‐ . Volkswagen AG not be shifted out of “N” position until brake pedal is depressed. gen AG does swa k Vol

y Selector lever in “P” position and ignition switched d b on se

•

Brake pedal not depressed:

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Brake pedal is depressed:


•


Selector lever is locked and cannot be shifted out of “P” position with the lock button pressed. Solenoid for selector lever lock blocks selector lever.

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Solenoid for selector lever lock releases selector lever. It is pos‐ sible to shift into a driving gear. Slowly shift selector lever from “P” through to “S”, checking whether selector lever position in dash panel insert corresponds to selector lever position. Selector lever in “N” position and ignition switched on •

Brake pedal not depressed:

Selector lever is locked and cannot be shifted out of “N” position with the lock button pressed. Solenoid for selector lever lock blocks selector lever. •

Brake pedal is depressed:

Selector lever in position “Tiptronic”

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AG.



48

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– Shift selector lever into Tiptronic gate.

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Solenoid for selector lever lock releases selector lever. It is pos‐ sible to shift into a driving gear.

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Symbols must change from “P R N D S” to “7 6 5 4 3 2 1”. Ignition and light switched on es, in part or in w l purpos hole ercia , is n m ot com


The respective symbol in the shift mechanism cover lights up.


AG. Volkswagen AG d agen oes ksw not l o gu yV b ara ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ d Golf Variant 2007 ➤ , Golf Variant 2010 e nte is r o eo h 7-speed dual clutch gearbox 0AM - Edition 07.2010 ut ra a c s s

Selector lever position display

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Simultaneous illumination of all selector lever position display segments indicates gearbox emergency running mode.


49

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3

Mechatronic unit for dual clutch gear‐ box -J743-

Safety note on mechatronic unit for dual clutch gearbox -J743⇒ page 50 Overview - mechatronic unit ⇒ page 51 Remove mechatronic unit for dual clutch gearbox -J743⇒ page 52 . Move mechatronic unit for dual clutch gearbox -J743- into “re‐ moval position” by hand ⇒ page 62 . Install mechatronic unit for dual clutch gearbox -J743⇒ page 65 . View of selector forks with mechatronic unit removed ⇒ page 72

3.1

Safety note on mechatronic unit for dual clutch gearbox -J743-

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50





Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 WARNING

Do not work on pressure accumulator. The accumulator is un‐ der pressure and is not allowed to be opened.

3.2

Overview - mechatronic unit

1 - Bolt ❑ 10 Nm ❑ M8 x 35 ❑ Always renew Note 2 - Bolt ❑ 10 Nm ❑ M8 x 90 ❑ Always renew 3 - Mechatronic unit for dual clutch gearbox -J743-




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Note

Take care with the breather when handling the mechatronic unit.

Protective cover -0AM 325 120- is well suited.

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– When doing any work on the mechatronic unit, please remove cap -arrow- from breather and seal with a suitable plug.

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3. Mechatronic unit for dual clutch gearbox J743

51



3.3

Removing mechatronic unit for dual clutch gearbox -J743- with gearbox in‐ stalled

This description only applies to installed gearboxes. If gearbox has been removed, first remove clutch then mechatronic unit. ♦ Move mechatronic unit for dual clutch gearbox -J743- into “re‐ moval position” by hand ⇒ page 62 . Special tools and workshop equipment required ♦ Assembly lever -T10407-




♦ Vehicle diagnostic tester


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♦ Drip tray for workshop hoist -VAS 6208-

Any retainers fitted on the cover of the mechatronic unit must also be removed.

Therefore, please follow description below step by step.

52


AG.

Mechatronic unit can be removed and inserted. When installing, make sure clutch plungers are correctly seated in cups of engag‐ ing levers.

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In this position, insert assembly lever -T10407- between release lever and gearbox housing. This makes it possible to remove load from plungers of mechatronic unit so that they may be removed by hand from cups of engaging levers.

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The vehicle diagnostic tester brings the mechatronic unit into the correct position for removal. All gear actuators are moved “into neutral”.

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In order to remove the mechatronic unit, sufficient space must be available in front of the gearbox. Depending on the vehicle, parts must be removed which do not have anything to do directly with the gearbox. For example, the air filter housing and, if present, charge air lines or coolant lines.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Note ♦ The clutch is self-adjusting. Shocks can have

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a an ss effect on this



adjusting device. Even if the mechatronic unit has been re‐ moved, the “sudden removal” of the assembly lever -T10407from under the engaging levers can have a negative effect on the adjusting mechanism.


♦ In order to remove the mechatronic unit, sufficient space must

be available in front of the gearbox. In some vehicles, parts must be removed which do not have anything to do directly with the gearbox. Remove any charge air lines or coolant lines that may be present.

♦ Any retainers fitted on the cover of the mechatronic unit must

also be removed.

♦ A “new” mechatronic unit is correctly filled with oil. ♦ Do not drain oil. A “removed” mechatronic unit is sent back

with its oil in.

Mechatronic unit remains filled with oil.

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– Connect vehicle diagnostic tester and then select “7-speed dual clutch gearbox”, Moving gear actuator into -neutral- position under Guided functions .

AG.

– Remove noise insulation ⇒ Rep. Gr. 50 ; Assembly overview - noise insulation .

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– Raise vehicle. All 4 supports of lifting platform must be at same height.

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Removing:

– Switch off ignition. – Raise vehicle. – Remove complete air filter housing. ♦ Vehicles with petrol engines ⇒ Rep. Gr. 24 ; Removing and installing air filter ♦ Vehicles with diesel engines ⇒ Rep. Gr. 23 ; Removing and installing air filter – Remove battery and battery tray ⇒ Rep. Gr. 27 ; Battery; Removing and installing battery .


53

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The cover prevents dirt getting in. Torque setting: 8 Nm – If this cover is fitted, remove it.

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– Place drip tray under gearbox.

– Drain gear oil, then reinstall drain plug ⇒ page 30 .

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– Release mechatronic unit connector by pulling in -direction of arrow- and pull off connector.

– Pull cap off breather and close using a suitable plug to achieve an oil-tight seal. Note

Protective cover -0AM 325 120- is well suited.

– Remove all retainers and brackets from front of gearbox.

54


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– Remove starter ⇒ Rep. Gr. 27 ; Removing and installing starter .



In some vehicles, a cover is fitted over the engaging levers.

2011 ➤


AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta Golf Variant 2007 ut ra a c s 7-speed dual s clutch gearbox 0AM - Edition 07.2010

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Using a screwdriver, carefully unclip gearbox input speed sender 3 -G641- from housing in -direction of arrow-.





– Unscrew bolts of mechatronic unit for dual clutch gearbox J743- “in diagonal sequence”. “There are 4 long and 3 short bolts.” Do not remove more than 7 bolts!

– Please look carefully to check which bolts you are unscrewing. Do not unscrew any cover bolts.

The gearbox is shown here again from the side to make this sit‐ uation clearer.

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Therefore, do not remove more than 7 bolts!

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The mechatronic unit must be removed. The cover does not have to be removed.

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The next step is “difficult”: Now press both engaging levers of dual clutch “away” from plung‐ ers of mechatronic unit. Otherwise, levers will jam mechatronic unit at plungers and prevent mechatronic unit from being re‐ moved. – Please read through this description all the way to the end first. This will help you to perform the following steps “correctly”. Both levers must now be carefully pressed away from the plung‐ ers. – First take a look at -reddish-brown- engaging lever in this pic‐ ture.


55





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56


– Insert assembly lever -T10407- to its right.






– Far enough until groove lines up with housing rib -arrow-.

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57

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•

Housing rib and groove of lever must be flush with one another. Do not insert tool as far as stop.

– Apply a bit of force to tip of lever when turning. This stops lever from slipping out when turning.

58


AG.

Caution

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– Assembly lever -T10407- should make contact with gearbox housing with its entire “rear face”.

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No further.




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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Turn assembly lever -T10407- anticlockwise. In this way, engag‐ ing levers are pressed away from plungers -direction of arrow-.

Do not take out assembly lever -T10407- . It must remain inserted between engaging lever and gearbox housing for the entire proc‐ ess. – If necessary, press assembly lever -T10407- against gearbox using a screwdriver.





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59

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60

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If lever slips off, this indicates you applied a bit of leverage to handle whilst turning.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Apply a bit of force to tip of lever when turning. This stops lever from slipping out when turning. – Remove mechatronic unit. Mechatronic unit remains filled with oil.

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If mechatronic unit “jams” and cannot be removed:

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o yV d bis to Mechatronic unit e ris ho ut a ss


61

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Sometimes, the mechatronic unit cannot be removed. In this case, the gear actuator is “caught” at the “top left” of the gearbox housing. In this case, mechatronic unit is not allowed to be removed with significant force. – First reposition mechatronic unit on gearbox housing and se‐ cure it with one bolt. – Move mechatronic unit into “removal position” by hand ⇒ page 62 . Installing mechatronic unit ⇒ page 65 .

3.4

Moving mechatronic unit for dual clutch gearbox -J743- into “removal posi‐ tion” by hand

Sometimes, the mechatronic unit cannot be removed. In this case, the gear actuator is “caught” at the “top left” of the gearbox housing -arrow-.

62


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Only if you cannot set the mechatronic unit to removal position with the vehicle diagnostic tester , you must move the unit by hand to this position.





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•

The “sticking” gear actuator -arrow- can be pressed by hand into its “removal position”. To do this, push a selector fork behind the parking lock cover. How to do this is described in the following work procedure: – First reposition mechatronic unit on gearbox housing and se‐ cure it with one bolt.

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63

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Prote cted by


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Remove securing clip in -direction of arrow-. Securing clips for selector lever cable must always be renewed.


– Use your hand to press lever to stop in direction of cable sup‐ port bracket.

– Remove lever of selector shaft. – Unbolt cover.

Caution

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– Working through opening, push selector fork to side -direction of arrow-. (Press to left in direction of travel.) This presses back “sticking” gear actuator and mechatronic unit can be removed. – Please do not assemble parking lock until you have filled oil.

64


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The mechatronic unit will not be “stuck” after the next step. That means that it could fall out. If not already done: Secure me‐ chatronic unit on gearbox with a bolt to prevent it from falling down.

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– Remove Bowden cable from ball head.



Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Grease oil seal in cover with sealing grease -G 052 128 A1- .




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– Fit cover and lever again.

– Press selector lever cable back onto ball head and install new securing clip. – Securing clips for selector lever cable must always be re‐ newed. – Add gear oil after completing work on mechatronic unit. Fill oil into gearbox ⇒ page 30 . – Adjust selector lever cable ⇒ page 43 . – Place plug on removed mechatronic unit.

AG.

♦ Guide pin -T10406-

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Installing mechatronic unit for dual clutch gearbox -J743-

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3.5


This way, the mechatronic unit can be sent sealed in oil-tight con‐ dition.


65

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Note ♦ A “new” mechatronic unit is correctly filled with oil. ♦ Do not drain oil. A “removed” mechatronic unit is sent back

with its oil in.

Installing •

All selector forks must be “in neutral” prior to installation of mechatronic unit Note

Make sure that all selector forks are located in -N-, “in the middle”, and therefore that the gearbox is in neutral.





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66

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– Therefore, check each of 4 selector forks by hand.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Every selector fork has 3 positions: “gear selected - neutral - gear selected”. – Also, move each fork into each position in succession. Then disengage all gears and return selector forks to middle position “neutral”. Note

“Neutral, neutral, neutral”, or gearbox will not function! You can turn the front gear slightly for assistance. This makes it “easier” to shift the forks. – Please clean sealing surface where mechatronic unit will make contact later on. Oil residues on sealing surface will later result in a misdiagnosis of “leaking”.

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– Screw in guide pin -T10406- hand-tight. Volksw

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Make sure that all 4 gear actuators project 25 millimetres -a-.

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67





Caution



Handle with care. When levering the plungers out of the me‐ chatronic unit, make sure that you do not brace yourself on the sensors. – Please clean sealing surface of mechatronic unit.

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68

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– Watch out for seal on

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Seal must be pushed in all around.

– Look at sender. Clip must not be damaged.



– Put on mechatronic unit.

– When gripping and putting on, make sure selector forks are not inadvertently pressed out of their position.

– Screw in 7 new bolts and tighten until finger-tight. ht rig py Co t.

– Remove guide pins -T10406- again.

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– Also observe engaging levers and plungers on mechatronic unit.

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– Make sure that plungers meet up correctly in cups of engaging levers. – Pull out plungers by hand until they are seated in cups. Plungers can be moved into position with a hook bent from a piece of welding wire (local manufacture). – Now check seat of plungers again.

Plungers that are not seated correctly will damage mechatronic unit. – Tighten mechatronic unit diagonally to 10 Nm.


69



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– Install gearbox input speed sender 3 -G641- .

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– Turn assembly lever -T10407- clockwise and remove it.


•


– Look at sender. Clip must not be damaged.

Sender lug must be fully and firmly in contact with gearbox housing. If sender is “loose” or clip is broken, renew mecha‐ tronic unit.

– Remove plug and put breather cap -arrow- in place. r te o iva r rp fo g n

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70

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– Attach all retainers and brackets to front of gearbox.

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– Join connector of mechatronic unit.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 In some vehicles, a cover is fitted over the engaging levers. The cover prevents dirt getting in. Torque setting: 8 Nm Now add gear oil ⇒ page 30 . – Install starter ⇒ Rep. Gr. 27 ; Removing and installing starter .

– Fit charge air or coolant hoses as necessary. – Install battery and battery tray ⇒ Rep. Gr. 27 ; Battery; Re‐ moving and installing battery . – Install complete air filter housing. ♦ Vehicles with petrol engines ⇒ Rep. Gr. 24 ; Removing and installing air filter ♦ Vehicles with diesel engines ⇒ Rep. Gr. 23 ; Removing and installing air filter olkswagen AG en AG. V and – If necessary, top up coolant ⇒ Rep. Gr. 19 does a;gDraining ksw not l o filling coolant . V gu y b ara d nte se i r – Install noise insulation⇒ Rep. Gr. 50 ; Assembly overview o eo h t u ra noise insulation . c sa s



–

Carrying out basic adjustment ⇒ page 7 .

Mechatronic unit remains filled with oil.


– Place plug on “removed” mechatronic unit if necessary. This way, the mechatronic unit can be sent sealed in oil-tight con‐ dition.

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71

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 en AG. Volkswagen AG

View of selector forks with mechatronic unit removed

5 - Gear 6 - Gear 7 - Gear

72


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4 - Gear


3 - Gear

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2 - Gear

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1 - Gear


Therefore, move me‐ chatronic unit into re‐ moval position by hand ⇒ page 65 .


R - Reverse gear ❑ If reverse gear is engag‐ ed, extended plunger of mechatronic unit catch‐ es behind gearbox housing.

ss


N - Idling/gearbox neutral po‐ sition “in the middle”

–

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3.6

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4

Removing and installing gearbox

Information about gearboxes with different output shafts ⇒ page 73 Vehicles with petrol engines 1.4 l/90 kW TFSI engine and 1.4 l/118 kW TSI engine ⇒ page 74 1.6 l/75 kW MPI engine ⇒ page 81 Vehicles with diesel engine 1.9 l/77 kW TDI PD engine ⇒ page 90


4.1


1.6 l/77 kW TDI CR engine ⇒ page 97



Information about gearboxes with differ‐ ent output shafts

Gearbox with different output shafts. A - Stub shafts “to 11.2008”

B - Flange shafts “from 12.2008”

Vehicles with stub shafts on gearbox

To remove gearboxes with stub shafts, it is necessary to remove stub shafts. Only shafts with straight joints can be put back onto the output shafts safely. Therefore, these drive shafts must be removed. Vehicles with flange shafts on gearbox

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Secure both drive shafts to suspension struts using tensioning straps -T10038- .

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For gearboxes with flange shafts, the drive shafts must be unbol‐ ted from the gearbox. This way, the gearbox can be removed. In individual cases, it is necessary to remove right-hand flange shaft from gearbox. This gives you enough clearance for removing gearbox.

4. Removing and installing gearbox

73


4.2

Removing gearbox, vehicles with 1.4 l/90 kW TFSI engine and 1.4 l/118 kW TSI engine . Volkswagen AG gen AG d

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♦ Support bracket -10 - 222 A-

♦ Adjustment plate -3282/59-


♦ Adapter -10 - 222 A /8♦ Insert tool, 18 mm -T10179♦ Gearbox support -3282♦ Socket -T10061-

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The gearbox is removed downwards separately, without engine. The battery, air filter and starter are removed “from above”.

74


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Brief description

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♦ Engine and gearbox jack -V.A.G 1383 A-

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 olkswagen AG Noise insulation beneath engine/gearbox, lower cover in frontagleft en AG. V does sw kbelow”. not l wheel housing and pendulum support are removed “from o V g

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height.



Only in vehicles with stub shafts Note

or ac ility ab y li an pt ce

–

After loosening centre bolt, do not lower vehicle to ground again. – Step on the brake pedal while a 2nd mechanic loosens the two drive shaft bolts -arrow-. – Remove both front wheels. Continuation for all vehicles

– Remove complete air filter housing ⇒ Rep. Gr. 24 ; Removing and installing air filter .

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– Remove battery and battery tray ⇒ Rep. Gr. 27 ; Battery; Removing and installing battery .

Prote cted by

– Remove starter ⇒ Rep. Gr. 27 ; Removing and installing starter .

– Remove securing clip in -direction of arrow-. Securing clips for selector lever cable must always be renewed. – Remove Bowden cable from ball head. Cable may also be pushed slightly backwards out of cable support bracket and removed later when gearbox is lowered. But then observe cable when lowering gearbox.


75

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Release mechatronic unit connector by pulling and pull off connector. – Now remove all upper connecting bolts between engine and gearbox.

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76

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These tools are appropriate for this.


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 A bolt is located in the starter motor hole. Bit -T10061- can be used instead of an 18 mm socket. – Remove noise insulation ⇒ Rep. Gr. 50 ; Assembly overview - noise insulation . – Remove front part of wheel housing ⇒ Rep. Gr. 66 ; Assembly overview - front wheel housing .


– Remove pendulum support. Only in vehicles with stub shafts

– Remove both drive shafts ⇒ Rep. Gr. 40 ; Removing and installing drive shafts . Only in vehicles with flange shafts





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– If fitted, remove the heat shield over the right-hand drive shaft. Tightening torque ⇒ Rep. Gr. 40 ; Repairing drive shafts


77

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Unbolt only left suspension link from swivel joint -arrows-. – Swing left drive shaft into wheel housing onto longitudinal member. This will keep the shaft out of the way during further work. The surface protection of the shafts must not be damaged. Plastic cable ties or a pair of tensioning straps -T10038- are therefore very good for this.


– Remove right flange shaft of gearbox.

Bolt has a 6 mm hexagon socket. Bolt can also be removed and installed with socket -V.A.G 1669- . Torque setting: 30 Nm Continuation for all vehicles

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78

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– Unbolt exhaust system bracket from subframe.





Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Remove front exhaust pipe so that lower bolts can be removed -arrows-. – Remove engine cover from cylinder head. n AG. Volkswagen AG do es n ot g ua ran tee or ac

age sup‐ – If there are hose and cable connections in area ofolengine ksw V y these now. port eye for support bracket -10-222 A- , remove db




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– Support engine and gearbox with support bracket -10-222 Abut do not raise.

AG.

In many cases, the spindle does not need to be lowered further for the later removal of the gearbox.

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At most, 5 turns are sufficient to remove bracket.

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– Then lower engine and gearbox slightly using spindles of sup‐ port bracket -10 - 222 A- so that bracket can be removed.

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Remove all bolts -1- and -2- for bracket.

To remove gearbox 0AM, set up gearbox support -3282- with ad‐ justment plate -3282/59- and push onto engine and gearbox support -V.A.G 1383 A- . – Align arms of gearbox support according to holes in adjust‐ ment plate -3282/59- . – Screw in support elements as illustrated on adjustment plate -3282/59- . – Position engine and gearbox jack -V.A.G 1383 A- under vehi‐ cle. •

Arrow on adjustment plate -3282/59- points in direction of trav‐ el.

– Align gearbox support -3282- parallel to gearbox. – Screw pin -3282/29- into “rear” hole for pendulum support.


79

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Place both remaining attachments onto gearbox as shown. When doing this, place sheet metal of drift under gearbox housing and not under mechatronic unit. n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran Raise gearbox and engine support -V.A.G 1383 A- from belowrised tee o h to support gearbox. t or u ac a ss

– Secure gearbox with tensioning strap -T10038- . –

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The gearbox is separated from the engine in this position. pe rm itte d

– Remove remaining engine/gearbox connecting bolts.


Note


– Press gearbox off engine, “observing selector lever cable” and lower gearbox.

♦ Distance between engine flange and gearbox flange should

be about 50 mm before gearbox is lowered.

♦ Be careful of all lines and coolant hoses when lowering gear‐

box.

Transporting gearbox and securing to assembly stand ⇒ page 111 .

– Install right flange shaft of gearbox with flange shafts ⇒ page 118 .

80


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– Remove retainers if installing a “new” gearbox, because there are no retainers on a “new” gearbox.

AG.

In some cases, there are retainers on the front of the gearbox.

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If gearbox is to be sent:

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Installing gearbox ⇒ page 104 .

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– Renew needle bearing in crankshaft -arrow- ⇒ Rep. Gr. 13 ; Crankshaft, pulling needle bearing from crankshaft and driving in .


4.3

Removing gearbox, vehicles with 1.6 l/75 kW MPI engine

Special tools and workshop equipment required ♦ Support bracket -10 - 222 A♦ Adjustment plate -3282/59♦ Adapter -10 - 222 A /8♦ Insert tool, 18 mm -T10179♦ Gearbox support -3282-


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♦ Bracket -T10346-


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♦ Socket -T10061-


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♦ Adapter -10 - 222 A /3-

Brief description The battery, air filter and starter are removed “from above”.

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– Raise vehicle. All 4 supports of lifting platform must be at same height. AG.

– Move selector lever to position “P” position. – Remove complete air filter housing ⇒ Rep. Gr. 24 ; Removing and installing air filter . – Remove battery and battery tray ⇒ Rep. Gr. 27 ; Battery; Removing and installing battery . – Remove starter ⇒ Rep. Gr. 27 ; Removing and installing starter .

82





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– Release mechatronic unit connector by pulling and pull off connector.

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– Now remove all upper connecting bolts between engine and gearbox.




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Cable may also be pushed slightly backwards out of cable support bracket and removed later when gearbox is lowered. But then observe cable when lowering gearbox.


83

AG.



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– Remove noise insulation ⇒ Rep. Gr. 50 ; Assembly overview - noise insulation . – Remove front part of wheel housing ⇒ Rep. Gr. 66 ; Assembly overview - front wheel housing .

84


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A bolt is located in the starter motor hole. Bit -T10061- can be used instead of an 18 mm socket.

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Remove all retainers and brackets from front of gearbox.

– Remove pendulum support.


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– Swing left drive shaft into wheel housing onto longitudinal member. This will keep the shaft out of the way during further work.

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The surface protection of the shafts must not be damaged. Plastic cable ties or a pair of tensioning straps -T10038- are therefore very good for this.


– Unbolt only left suspension link from swivel joint -arrows-.


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– Disconnect left and right-hand drive shafts from flanges on gearbox.


85

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Secure both drive shafts to suspension struts using tensioning straps -T10038- .

– Remove right flange shaft of gearbox. AG. Volkswagen A

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Torque setting:u30 tho Nm

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– Remove front exhaust pipe so that lower bolts can be removed -arrows-.


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86

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– Remove engine cover from cylinder head.

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– Unbolt exhaust system bracket from subframe.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Bolt bracket -T10346- to rear of the 3 mounting holes for bat‐ tery tray. – To do this, use a collar bolt M 6 or a securing bolt for battery AG. Volkswagen AG d tray. agen oes w s k n ol yV

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– Set up support bracket -10-222 A- in front of bonnet support. – Use: ♦ Adapter -10 - 222 A /8♦ Adapter -10 - 222 A /3•

Place adapters -10 - 222 A /8- on upper longitudinal carriers, directly before the raised portion (-arrow 1-) next to bolt (-arrow 2-).


87

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Connect left support eye on engine to support bracket . – Connect bracket -T10346- to support bracket (⇒ previous il‐ lustration). – Take up weight of engine/gearbox assembly and support bracket on spindles. olkswagen AG en AG. V ag ksw

does not gu ara d e nte is r o eo Then lower engine and gearbox slightly using spindles of sup‐ h ut ra a port bracket -10 -ss222 A- so that bracket can be removed. c

Vol Remove all bolts -1- and -2- for by bracket.


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At most, 5 turns are sufficient to remove bracket.

To remove gearbox 0AM, set up gearbox support -3282- with ad‐ justment plate -3282/59- and push onto engine and gearbox support -V.A.G 1383 A- . – Align arms of gearbox support according to holes in adjust‐ ment plate -3282/59- .

– Position engine and gearbox jack -V.A.G 1383 A- under vehi‐ cle. Arrow on adjustment plate -3282/59- points in direction of trav‐ el. agen lksw Vo by


– Align gearbox support -3282- parallel to gearbox.

– Screw pin -3282/29- into “rear” hole for pendulum support. AG.

– Place both remaining attachments onto gearbox as shown. When doing this, place sheet metal of drift under gearbox housing and not under mechatronic unit. – Secure gearbox with tensioning strap -T10038- . – Raise gearbox and engine support -V.A.G 1383 A- from below to support gearbox. The gearbox is separated from the engine in this position. – Remove remaining engine/gearbox connecting bolts. – Press gearbox off engine, “observing selector lever cable” and lower gearbox. Note ♦ Distance between engine flange and gearbox flange should



box.

88


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– Screw in support elements as illustrated on adjustment plate -3282/59- .

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 . Volkswage

–

Installing gearbox ⇒ page 104 . If gearbox is to be sent:

In some cases, there are retainers on the front of the gearbox. – Remove retainers if installing a “new” gearbox, because there are no retainers on a “new” gearbox.

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– Install right flange shaft ⇒ page 118 .



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Transporting gearbox and securing to assembly stand ⇒ page 111 .

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89

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4.4

Removing gearbox - vehicles with 1.9 l/77 kW TDI PD engine

Special tools and workshop equipment required ♦ Support bracket -10 - 222 A♦ Adapter -10 - 222 A /8♦ Socket -T10061un le pe rm itte d


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♦ Adapter -10 - 222 A /16-

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♦ Insert tool, 18 mm -T10179-


♦ Gearbox support -3282-


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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 ♦ Hook -10 - 222 A /2-


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♦ Shackle -10 - 222 A /12-



Brief description The gearbox is removed downwards separately, without engine. The battery, air filter and starter are removed “from above”. Noise insulation beneath engine/gearbox, lower cover in front left wheel housing and pendulum support are removed “from below”. Perform the following steps: – Raise vehicle. All 4 supports of lifting platform must be at same height. – Move selector lever to position “P” position. Only in vehicles with stub shafts Note

After loosening centre bolt, do not lower vehicle to ground again.


91

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Step on the brake pedal while a 2nd mechanic loosens the two drive shaft bolts -arrow-. – Remove both front wheels. Continuation for all vehicles – Remove complete air filter housing ⇒ Rep. Gr. 23 ; Removing and installing air filter .

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– Remove securing clip in -direction of arrow-. Securing clips for selector lever cable must always be renewed. – Remove Bowden cable from ball head.

– Release mechatronic unit connector by pulling and pull off connector. agen lksw Vo by


– Now remove all upper connecting bolts between engine and gearbox. Prote cted by

92


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– Remove noise insulation ⇒ Rep. Gr. 50 ; Assembly overview - noise insulation . agen lksw Vo by

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– Remove front part of wheel housing ⇒ Rep. Gr. 66 ; Assembly overview - front wheel housing . AG.

Only in vehicles with stub shafts – Remove both drive shafts ⇒ Rep. Gr. 40 ; Removing and installing drive shafts . Only in vehicles with flange shafts – If fitted, remove the heat shield over the right-hand drive shaft. Tightening torque ⇒ Rep. Gr. 40 ; Repairing drive shafts


93

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Unscrew left suspension link from swivel joint. – Swing left drive shaft into wheel housing onto longitudinal member. This will keep the shaft out of the way during further work. The surface protection of the shafts must not be damaged. Plastic cable ties or a pair of tensioning straps -T10038- are therefore very good for this.


– Remove right flange shaft of gearbox. Bolt has a 6 mm hexagon socket. Bolt can also be removed and AG. Volkswagen AG d installed with socket -V.A.G 1669- . agen o Torque setting: 30 Nm


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Continuation for all vehicles


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94

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Remove pendulum support. – Remove engine cover from cylinder head. – If there are hose and cable connections in area of engine sup‐ port eye for support bracket -10 - 222 A- , remove these now. – Remove filler pieces from upper edges of both wings.





Secure shackle -10 - 222 A /16-

AG. Volkswagen AG d agen oes ksw not l o V to gearbox housing. gu y b ara d nte ise r o eo h t u ra a c s s

Remove all bolts -1- and -2- for bracket. – Then lower engine and gearbox slightly using spindles of sup‐ port bracket -10 - 222 A- or adapter -10 - 222 A /16- so that bracket can be removed. At most, 5 turns are sufficient to remove bracket.

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In many cases, the spindle does not need to be lowered further for the later removal of the gearbox.

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95

AG.

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 To remove gearbox 0AM, set up gearbox support -3282- with ad‐ justment plate -3282/59- and push onto engine and gearbox support -V.A.G 1383 A- . . Volkswage

n Gd AG – Align arms of gearbox support agen according to Aholes oesin adjust‐ ksw not l o V gu ment plate -3282/59by . a

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– Align gearbox support -3282- parallel to gearbox. – Screw pin -3282/29- into “rear” hole for pendulum support.

– Place both remaining attachments onto gearbox as shown. When doing this, place sheet metal of drift under gearbox housing and not under mechatronic unit. – Secure gearbox with tensioning strap -T10038- . – Raise gearbox and engine support -V.A.G 1383 A- from below to support gearbox. The gearbox is separated from the engine in this position. ht rig py Co t.


– Remove remaining engine/gearbox connecting bolts.

– Press gearbox off engine, “observing selector lever cable” and lower gearbox. agen lksw Vo by

AG.

Note ♦ Distance between engine flange and gearbox flange should



box.

– Renew needle bearing in crankshaft -arrow- ⇒ Rep. Gr. 13 ; Crankshaft, pulling needle bearing from crankshaft and driving in . Transporting gearbox and securing to assembly stand ⇒ page 111 . Installing gearbox ⇒ page 104 . If gearbox is to be sent:

96



Arrow on adjustment plate -3282/59- points in direction of trav‐ el.

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– Position engine and gearbox jack -V.A.G 1383 A- under vehi‐ cle.


tee r – Screw in support ho elements as illustrated on adjustment plate or ut ac a -3282/59- .ss

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 In some cases, there are retainers on the front of the gearbox. – Remove retainers if installing a “new” gearbox, because there are no retainers on a “new” gearbox.

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♦ Socket -T10061♦ Gearbox support -3282♦ Insert tool, 18 mm -T10179-

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♦ Socket -T10035-

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♦ Support bracket -10 - 222 A-

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Removing gearbox - vehicles with 1.6 l/77 kW TDI CR engine


4.5

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olks – Install right flange shaft of gearbox with flange shafts yV b d ⇒ page 118 . ise


97

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 ♦ Adapter -10 - 222 A /3-

♦ Adapter -10 - 222 A /18-




Brief description



The gearbox is removed downwards separately, without engine. The battery, air filter and starter are removed “from above”. Noise insulation beneath engine/gearbox, lower cover in front left wheel housing and pendulum support are removed “from below”. Perform the following steps:

– Raise vehicle. All 4 supports of lifting platform must be at same height. – Move selector lever to position “P” position.

AG.


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98

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– Remove complete air filter housing ⇒ Rep. Gr. 23 ; Removing and installing air filter .

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– Remove engine cover from cylinder head.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Remove battery and battery tray ⇒ Rep. Gr. 27 ; Battery; Removing and installing battery . – Remove starter ⇒ Rep. Gr. 27 ; Removing and installing starter .

– Remove securing

– Remove Bowden cable from ball head.



– Release mechatronic unit connector by pulling and pull off connector. – Now remove all upper connecting bolts between engine and gearbox.

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Securing clips for selector lever cable must always be renewed.


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99





– Remove noise insulation ⇒ Rep. Gr. 50 ; Assembly overview - noise insulation . – Remove front part of wheel housing ⇒ Rep. Gr. 66 ; Assembly overview - front wheel housing .



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100

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Unscrew left suspension link from swivel joint. – Swing left drive shaft into wheel housing onto longitudinal member. This will keep the shaft out of the way during further work. The surface protection of the shafts must not be damaged. Plastic cable ties or a pair of tensioning straps -T10038- are therefore very good for this.


– Remove right flange shaft of gearbox. . Volkswagen AG Bolt has a 6 mm hexagon socket. Bolt can also be removed AGand does agen ksw installed with socket -V.A.G 1669- . not l o V

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101

AG.


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Remove pendulum support. – If there are hose and cable connections in area of engine sup‐ port eye for support bracket -10-222 A- , remove these now. – Remove filler pieces from upper edges of both wings.




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102


Place adapters -10 - 222 A /8- on upper longitudinal carriers, directly before the raised portion (-arrow 1-) next to bolt (-arrow 2-).

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Remove all bolts -1- and -2- for bracket. – Then lower engine and gearbox slightly using spindles of sup‐ port bracket -10 - 222 A- so that bracket can be removed. At most, 5 turns are sufficient to remove bracket. In many cases, the spindle does not need to be lowered further for the later removal of the gearbox.

To remove gearbox 0AM, set up gearbox support -3282- with ad‐ justment plate -3282/59- and push onto engine and gearbox support -V.A.G 1383 A- . – Align arms of gearbox support according to holes in adjust‐ ment plate -3282/59- . – Screw in support elements as illustrated on adjustment plate -3282/59- . – Position engine and gearbox jack -V.A.G 1383 A- under vehi‐ cle. •

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a – Screw pin -3282/29- into “rear” holess for pendulum support.

– Place both remaining attachments onto gearbox as shown. When doing this, place sheet metal of drift under gearbox housing and not under mechatronic unit. – Secure gearbox with tensioning strap -T10038- . – Raise gearbox and engine support -V.A.G 1383 A- from below to support gearbox. The gearbox is separated from the engine in this position. – Remove remaining engine/gearbox connecting bolts. – Press gearbox off engine, “observing selector lever cable” and lower gearbox.



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box.

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♦ Distance between engine flange and gearbox flange should

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Note


103

Volkswagen AG Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta g2011 n AG.➤ does wa e s k not l o 7-speed dual clutch gearbox 0AM - Edition 07.2010 g yV

Transporting gearbox and securing to assembly stand ⇒ page 111 . If gearbox is to be sent:


Installing gearbox ⇒ page 104 .

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in .


–

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b ed ris o h ; Renew needle bearing in crankshaft -arrow- ⇒ Rep. Gr. ut13 sa Crankshaft, pulling needle bearing from crankshaft andsdriving

In some cases, there are retainers on the front of the gearbox. – Remove retainers if installing a “new” gearbox, because there are no retainers on a “new” gearbox. – Install right flange shaft of gearbox with flange shafts ⇒ page 118 .


Prote cted by

104

AG.

– In some cases, there are brackets on the front of the removed gearbox. Attach these brackets to the “new” gearbox.

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– Please read these important work steps before installing gear‐ box.

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Installing gearbox

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4.6

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 In some vehicles, a cover is fitted over the engaging levers. The cover prevents dirt getting in.



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Gearbox with stub shafts -AGearbox with flange shafts -Bes, in part or in w l purpos hole ercia , is n m ot com

Note

There is no need to renew oil seal for flange shaft when doing this. – Remove right-hand flange shaft of gearbox in order to install gearbox. Gearbox with flange shafts, torque setting ⇒ page 118 .

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Bolt has a 6 mm hexagon socket. Bolt can also be removed and installed with socket -V.A.G 1669- .


– In gearboxes with flange shafts, flange shaft must be reinstal‐ led on “new” gearbox in some cases ⇒ page 114 .


105

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AG.


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – If it has not already been done, renew needle bearing in crank‐ shaft -arrow- ⇒ Rep. Gr. 13 ; Crankshaft, pulling needle bearing from crankshaft and driving in . – Check for proper seating of both dowel sleeves between en‐ gine and gearbox. – Check for proper seating of intermediate plate. – Guide selector lever cable as soon as possible into its support bracket.

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Bowden cable must not be greased.

It must be possible to guide the engine and gearbox together by hand until the engine flange and gearbox flange make contact all around. If not, “something has gone wrong”!

– Readjust gearbox support until engine and gearbox are “aligned with each other”. – Turn crankshaft slightly if necessary.

106


Prote cted by

– Therefore, when installing, always use a “new” securing clip.

AG.

A securing clip which has been removed is not allowed to be in‐ stalled again. The clip will have lost its internal tension and so it might fall off.

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– Securing clip for selector lever Bowden cable -arrow- must be renewed.

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– After fitting starter motor, check that both breather caps are in place -arrows-!



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Check Bowden cable as soon as gearbox is raised. Be sure to insert it in cable support bracket “early”.

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– Ensure that selector lever cable is properly routed during in‐ stallation -arrow-. es, in part or in w l purpos hole ercia , is n m ot com

– Observe sheet metal. Press it back up in the tunnel during installation. – Always adjust selector lever cable ⇒ page 43 . –

Carrying out basic adjustment ⇒ page 7 .

Torque settings for gearbox installation ⇒ page 107 .

Torque settings “Gearbox to engine” and notes on assembly mounting


4.7

There is also information about the “left” assembly mounting.

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The “next chapters” list the torque settings for gearbox installa‐ tion.


If the sheet metal has been bent downwards when the gearbox was removed, it may cause noises. The cable will vibrate against the sheet metal.

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Threaded connections that are not directly assigned to the gear‐ box can be found in the associated assembly groups. agen lksw Vo by

For example: subframe and pendulum support. AG.

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The pendulum support on the subframe is part of the running gear. Consequently, further descriptions can also be found in ⇒ Run‐ ning gear, axles, steering; Rep. Gr. 40 . Left assembly mounting – Renew all bolts on left assembly mounting. – First screw in all bolts by hand.

– First bolt bracket to gearbox -1- with 40 Nm + 90° further turn.


107

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 . Volkswage

n AG – The bracket can be moved within its seat with agaenscrewdriver AG does ksw not l o V of -bolts 2-: 60 Nm gu when bolts -2- are tightened. Torque setting by ara d e nte + 90°. ris ho ut

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Pendulum support to subframe and gearbox ⇒ Rep. Gr. 40 ; Assembly overview - subframe, anti-roll bar, suspension links . Gearbox to engine:

♦ 1.4 l/90 kW TFSI engine ⇒ page 108 ♦ 1.4 l/118 kW TSI engine ⇒ page 108 ♦ 1.6 l/75 kW MPI engine ⇒ page 108 ♦ 1.9 l/77 kW TDI PD engine ⇒ page 109 ♦ 1.6 l/77 kW TDI CR engine ⇒ page 110

4.7.1

Engines: 1.4 l/90 kW TFSI, 1.4 l/118 kW TSI, 1.6 l/75 kW

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108


- Arrows point towards dowel sleeves

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M10 - 40 Nm

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M12 - 80 Nm ❑ If insert 18 mm -T10179is used: 65 Nm.




Starter to gearbox ⇒ Rep. Gr. 27ss;aRemoving and installing start‐ er .


4.7.2

Engine: 1.9 l/77 kW TDI PD

M12 - 80 Nm ❑ If 18 mm insert -T10179is used: 65 Nm. M10 - 40 Nm


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109

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4.7.3

Engine: 1.6 l/77 kW TDI CR

M12 - 80 Nm ❑ If 18 mm insert -T10179is used: 65 Nm. M10 - 40 Nm


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110




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Transporting gearbox


– Pull off both breather caps -arrows- and close using suitable plugs to achieve an oil-tight seal.

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Transporting gearbox and securing to assembly stand


5

olksw en AG en AG. V 2007ag➤ doesVariant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ Golf Variant , Golf ag ksw not l o gu yV 7-speed dual b ara clutch gearbox 0AM - Edition 07.2010 d e nte is r o eo h ut ra a c s s

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Secure gearbox on gearbox support -VW 353-

5. Transporting gearbox and securing to assembly stand

111

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Lift gearbox into assembly stand. G do es n ot g ua ran tee or ac

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The gearbox is lifted “into assembly stand” together with gearbox support -VW 353- . n AG. Volkswagen A


35 –

Gears, shafts

1

Currently, no repairs can be made to gears and shafts





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1. Currently, no repairs can be made to gears and shafts

113


39 –

Final drive - front differential

1

Oil seals

Gearbox with stub shafts -A-. Right ⇒ page 114 Left ⇒ page 116 Gearbox with flange shafts -B-. Right ⇒ page 118



1.1


Left ⇒ page 120


Renewing oil seal for right stub shaft

Left-hand side ⇒ page 116

Special tools and workshop equipment required ♦ Thrust piece -3305-

Prote cted by

Rep. Gr.39 - Final drive - front differential

AG.

114

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♦ Hexagon key -T10107 A- or socket and extended bit -V.A.G 1669-

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 ♦ Sealing grease -G 052 128 A1♦ Drip tray Perform the following steps: Note ♦ Do not remove both drive shafts from gearbox at the same

time. If you do so, it will no longer be possible to hold the op‐ posite front wheel fixed for removing or installing the bolts of the stub shafts.

♦ Do not remove both stub shafts from gearbox at the same time.

If the differential bevel gears turn, it is difficult to reinstall the securing bolts for the stub shafts.

– Remove drive shaft ⇒ Rep. Gr. 40 ; Removing and installing drive shafts . – Place drip tray under gearbox. – Remove bolt -arrow- in stub shaft with socket -T10107 A- or socket -V.A.G 1669- . – Pull out stub shaft. – Pry seal out using assembly lever. G. Volkswage nA wage

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s no olks – Lightly oil outer t gu y V circumference of new oil seal.

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

– Drive in new seal to stop, being careful not to cant seal.




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If necessary, it is possible to press a new dust ring onto the stub shaft using tube -2010- . Do not use a hammer. ht rig py Co t.


– Insert stub shaft.

– Tighten new countersunk bolt for stub shaft to 30 Nm. agen lksw Vo by

– Reinstall drive shaft ⇒ Rep. Gr. 40 ; Removing and installing drive shafts . AG.

– Renew gear oil ⇒ page 30 . – Install noise insulation; torque settings ⇒ Rep. Gr. 50 ; As‐ sembly overview - noise insulation .

1. Oil seals

115

Renewing oil seal for left stub shaft es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

Right side ⇒ page 114 .


1.2

AG. Volkswagen AG d agen oes ksw not l o V gu Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta by 2005 ➤ , Jetta 2011 ➤ ara d e nte s i r 7-speed dual clutch gearbox 0AM - Edition 07.2010 o eo h ut ra a c s s

♦ Thrust piece -3305-



116


AG.


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♦ Puller hooks -771/37-

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♦ Multipurpose tool -771-

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 ♦ Torque wrench -V.A.G 1332♦ Sealing grease -G 052 128 A1♦ Drip tray Perform the following steps: Note ♦ Do not remove both drive shafts from gearbox at the same

time. If you do so, it will no longer be possible to hold the op‐ posite front wheel fixed for removing or installing the bolts of the stub shafts.

♦ Do not remove both stub shafts from gearbox at the same time.

If the differential bevel gears turn, it is difficult to reinstall the securing bolts for the stub shafts.

– Remove drive shaft ⇒ Rep. Gr. 40 ; Removing and installing drive shafts . – Place drip tray under gearbox. – Remove bolt -arrow- in stub shaft with socket -T10107 A- or socket -V.A.G 1669- . – Pull out stub shaft.

– Pull out stub shaft oil seal with multi-purpose tool -VW 771n AG. Volkswagen AG do and puller hooks -VW 771/37-. e wage

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by tool -T20143- . Seal can also be removed using extractor ed

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th – Lightly oil outer circumference au of new oil seal.

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

1. Oil seals

117

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AG.


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Drive in new seal to stop, being careful not to cant seal. If necessary, it is possible to press a new dust ring onto the stub shaft using drift sleeve -40 - 20- . Do not use a hammer. – Insert stub shaft. – Tighten new countersunk bolt for stub shaft to 30 Nm. – Reinstall drive shaft ⇒ Rep. Gr. 40 ; Removing and installing drive shafts . – Renew gear oil ⇒ page 30 . – Install noise insulation; torque settings ⇒ Rep. Gr. 50 ; As‐ sembly overview - noise insulation .

1.3

Renewing seal for right flange shaft

Left-hand side ⇒ page 120 Special tools and workshop equipment required


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AG.

118

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♦ Tensioning strap -T10038-

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ AG. Volkswagen AG7-speed dual clutch gearbox 0AM - Edition 07.2010 do agen

♦


♦ Drip tray


♦ Do not remove both flange shafts from gearbox at the same

time. If the differential bevel gears turn, it is difficult to reinstall the securing bolts for the flange shafts.

♦ Remove drive shaft from gearbox and lay to side. Drive shaft

is fixed onto suspension strut with tensioning belt -T10038- .

♦ You do not need to remove the centre bolt of the drive shaft. – Remove noise insulation ⇒ Rep. Gr. 50 ; Assembly overview - noise insulation . – Remove drive shaft heat shield from engine -arrows-, if fitted. Unbolt drive shaft from gearbox. ht rig py Co t.



Note

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♦


w olks yV b ed Torque wrench -V.A.G 1332ris ho t au -G 052 128 A1Sealing grease ss


– Raise drive shaft as high as possible and secure. Take care not to damage paint on drive shaft in the process. agen lksw Vo by

AG.

– Remove right flange shaft of gearbox. Bolt has a 6 mm hexagon socket. Bolt can also be removed and installed with socket -V.A.G 1669- . – Pull out flange shaft. – Pry seal out using assembly lever. – Lightly oil outer circumference of new oil seal.

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

1. Oil seals

119

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Drive in new seal to stop with thrust piece -3305- , being careful not to cant seal. – Insert flange shaft. – Tighten new countersunk bolt to 30 Nm. When doing this, press flange shaft against gearbox so that bolt engages in thread. – Fit drive shaft back on ⇒ Rep. Gr. 40 ; Removing and installing drive shafts . – Renew gear oil ⇒ page 30 . – Install noise insulation; torque settings ⇒ Rep. Gr. 50 ; As‐ sembly overview - noise insulation .

1.4

Renewing oil seal for left flange shaft

Right side ⇒ page 118 Special tools and workshop equipment required ♦ Multipurpose tool -VW 771-






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120

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♦ Tensioning strap -T10038-

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 AG. Volkswagen AG d agen o

es n lkswor socket and extended ♦ Hexagon key -T10107VoAbitot -V.A.G gu y b ara d 1669e n s

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♦ Torque wrench -V.A.G 1331♦ Torque wrench -V.A.G 1332♦ Sealing grease -G 052 128 A1♦ Drip tray


♦ Do not remove both securing bolts in left and right flange shafts

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Note

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at the same time. If the differential bevel gears turn, it is difficult to reinstall the bolts. agen lksw Vo by

♦ Remove drive shaft from gearbox and carefully lay to side. AG.

Drive shaft is fixed onto suspension strut with tensioning belt -T10038- .

♦ You do not need to remove the centre bolt of the drive shaft. – Remove noise insulation ⇒ Rep. Gr. 50 ; Assembly overview - noise insulation . – Remove left wheel housing liner⇒ Rep. Gr. 66 ; Assembly overview - front wheel housing liner . – If present: Unbolt front left vehicle level sender -G78- from suspension link. Torque setting for removing and installing ⇒ Rep. Gr. 40 ; front left vehicle level sender -G78- . – Turn steering wheel to left lock and remove left drive shaft from flange shaft ⇒ Rep. Gr. 40 ; Removing and installing drive shafts .

1. Oil seals

121

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Only unscrew left suspension link from swivel joint.

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– Swing left drive shaft into wheel housing.


–

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–

AG. Volkswagen AG d agen oes ksw not l o gu Unscrew nut -1- from coupling rod -3- ⇒ Rep. Gr. 40 ; As‐ d by V ara e nte is. r sembly overview - subframe, anti-roll bar, suspension links o eo h ut ra a c s Pull off coupling rod and turn anti-roll bar -2- upwards sslightly.

– Remove left flange shaft of gearbox.




– Raise drive shaft as high as possible and secure. Take care not to damage paint on drive shaft in the process.

Bolt has a 6 mm hexagon socket. Bolt can also be removed and installed with socket -V.A.G 1669- .



AG.

122

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– Lightly oil outer circumference of new oil seal.

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– Remove flange shaft oil seal.

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– Pull out flange shaft.

sealing grease -G 052 128- -arrow-.

– Drive in new seal to stop with thrust piece -3305- , being careful not to cant seal. – Insert flange shaft.

– Fit drive shaft back on ⇒ Rep. Gr. 40 ; Removing and installing drive shafts .

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– Tighten new countersunk bolt to 30 Nm. When doing this, press flange shaft against gearbox so that bolt engages in thread.



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–

n AG. Volkswagen AG do es n wage s k l o➤ o 2007 ➤ , Golf Variant 2010 Golf Variant t gu, Jetta 2005 ➤ , Jetta 2011 ➤ yV b ara d 7-speed dual clutch gearbox nte 0AM - Edition 07.2010 ir se eo ho t u ra a c ss Half-fill space between sealing lip and dust lip of new seal with

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Prote cted by


– Fit suspension link and coupling rod back on ⇒ Rep. Gr. 40 ; Removing and installing drive shafts . – Renew gear oil ⇒ page 30 . – Install noise insulation; torque settings ⇒ Rep. Gr. 50 ; As‐ sembly overview - noise insulation .

1. Oil seals

123

7-Speed Dual Clutch Gearbox 0AM

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