6-speed dual clutch gearbox 02E.pdf

ServiceWorkshop Manual Golf Variant 2007 ➤ Golf Variant 2010 ➤ Jetta 2005 ➤ Jetta 2011 ➤ Edition 07.2010 6-speed dual clutch gearbox 02E urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p un le n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en r fo ng Service Department. Technical Information ht rig py Co t. agen lksw Vo by AG. Prote cted by c o p yri gh t . C op yi Service List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups Repair Group 00 - Technical data 30 - Clutch 34 - Controls, housing 35 - Gears, shafts 39 - Final drive - differential urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p un le AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en r fo ng 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 MEX5R006620 ht rig py Co t. agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o e➤ h t or , Golf Variant 2007 ➤ , Golf Variant 2010 u ac a s s Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed dual clutch gearbox 02E - Edition 07.2010 ility ab y li an pt ce Contents 00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 2 2.1 2.2 2.3 3 3.1 4 4.1 5 1 2 2.1 2.2 2.3 2.4 2.5 1 1.1 1.2 1.3 2 2.1 2.2 3 3.1 3.2 4 5 5.1 5.2 5.3 5.4 5.5 5.6 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-rings, seals and gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual clutch gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General notes on fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Useful information about the „behaviour of the control unit in the event of a gearbox fault“ ........................................................................ Special notes on fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reading gearbox code letters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Code - engine allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identification code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . do c um en rrectness of i t to the co nform spec at i h re o n wit in t his 1 1 2 2 3 3 4 5 6 7 7 7 8 10 10 13 13 14 15 16 16 18 21 22 24 31 31 40 49 51 51 52 54 54 56 58 60 60 61 68 69 70 70 30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Notes on clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing clutch cover (end cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing clutch cover (end cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preparing installation of multi-clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing and adjusting clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical and electronic components for the dual clutch gearbox and their locations . . . . Removing and installing mechatronic unit for dual clutch gearbox J743 (gearbox installed) ........................................................................ Removing and installing mechatronic unit for dual clutch gearbox J743 (gearbox removed) ........................................................................ Removing and installing gearbox input speed sender G182 and oil temperature sender in multi-plate clutch G509 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing gearbox oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing gearbox oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing gearbox oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renew seal on selector shaft lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview - selector mechanism in vehicles up to 02.2009 . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing selector lever cable - vehicles up to 02.2009 . . . . . . . . . . . . . . . . Overview of selector mechanism - vehicles from 03.2009 onwards . . . . . . . . . . . . . . . . . . Removing and installing selector mechanism with selector lever and selector lever cable vehicles from 03.2009 onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contents 34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 ht rig py Co t. agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi i . . . . . . . . . . . . . . . . . . . Transporting gearbox and securing to assembly stand . . . . . .2010 5. . . . . . . . . . . . . . . . . . . . . .. . . . 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .1 6. . . . . . . . . . . . . . .o. . . . . . . . . . . .a. . . . ..1 1 1 1. . . . . . . . . . . . . . . . . . . . .a. . . .. . . . . . . . . . . Checking selector mechanism . . . . . .Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . is n m ot p om c r erm o e t a itte riv du p or nl f e g n 72 73 74 76 76 86 87 89 90 92 95 96 96 98 35 . . . . . Prote cted by c o py rig ht . . . . . . . . Jetta 2005 ➤ . .8 5. . . .V. . .n . Removing and installing selector lever knob .d . .. . . . . . . . . . . . . . . . . . . . .A . . . . . . . . . . . . . . . . . . . . . . in part or in w l purpos hole ercia . . . . . . . . . . e. Renewing oil seal for left flange shaft . . . . . . . . . . 95 Currently.t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w . . . . . db ra. . . c. . . . . . . . . . .2 Emergency release of selector lever . . . . . . . . . . . . .a. . . . . . . . es. . . . . .9 6 6. . . . . agen lksw Vo by AG. . . . . Renewing seals for right flange shaft or stub shaft . . . . y. . . . . . . . . . . . . . . . . . . . . . . . . .o . e nte s i r Removing gearbox . s s Torque settings .Golf Variant 2007 ➤ . . C op yi . . . . . . . . . . . . . . .. . . . . . . . . . . . . .ge . . . . . . Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . .. . . no repairs can be made to gears and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .differential . Golf Variant 2010 ➤ . . . . . . . . . . . . . . . . . . .Final drive . . . . . . . . . . . . . . . . .. . . . . . 96 ility ab y li an pt ce rrectness of i t to the co nform spec at i h re o n wit in t his do c um en ii Contents ht rig py Co t. . . . . . . . . . o h r au Installing gearbox . ..G . . . . . . . .e. . . . . . . . . . . . . . . . . . . . . .1 1. . . .. . . . . . . . . . shafts ..3 7 8 8. Renewing seals for flange shaft or stub shaft . . . . . . . . . . . . . t. . . . . . . . . . . . . kswagen AG ol. . . . . Changing oil and filter . . . . .2 6. . . . . . . . . . . .. . . . . . . . . . Changing oil and filter and adjusting oil level . . . . s no ks l o V gu Removing and installing gearbox . . . . . . . . . .7 5. . . . . . . . . . . .. . .Edition 07. . . . The Dual Clutch Gearbox 02E . If you use ⇒ ELSA. Jetta 2005 ➤ . Golf Variant 2010 ➤ . You can gain further information from the ⇒ CD ROM ⇒ Multimedia training. is n m ot com pe rm itte d un le AG. – You can do this by clicking the ⇒ Feedback button at the top in the menu bar.2010 00 – 1 Technical data General repair notes es. C op yi 1. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s It should support you and be an aid to you. in part or in w l purpos hole ercia . do c um en You can learn more about how the gearbox works in ⇒ Self-study programme No.Golf Variant 2007 ➤ . r te o iva r rp fo g n This workshop manual was written for you. agen lksw Vo by Prote cted by c o p yri gh t. 308 . Dual clutch gearbox . you can send Volkswagen suggestions and comments from any‐ where in the world. More information on the dual clutch gearbox ⇒ DSG® AG.Edition 07. General repair notes 1 . Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . ht rig py Co t. In particular. Jetta 2005 ➤ . aut c s s Tools The catalogue is also available on ⇒ CD-ROM and can be ordered the usual way from Bertelsmann.A. do not remove Genuine parts from packaging until immediately before installing. ♦ When installing the gearbox. Torque wrench -V. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng AG. in part or in w l purpos hole ercia .2010 1. agen lksw Vo by AG.1 Uncertainty often occurs with smaller bolts having low tightening forces. ♦ If repair work cannot be performed immediately.Edition 07. ♦ First thoroughly clean connecting points and surrounding areas and then loosen bolts. do not run engine or tow vehicle. Volkswagen AG d agen oes ksw not l o V gu A summary of the special tools and workshop equipment used in by ara d e nte is r the workshop manual precedes each repair procedure and can o eo h ra be found in „Special tools/Workshop equipment“ binder. dirt entering an »exposed« mechatronic unit for dual clutch gearbox -J743.00 . C op yi thi sd o cu m en ♦ If gearbox covers have been unbolted or gearbox has no fluid. Prote cted by c o p yri gh t. Golf Variant 2010 ➤ . carefully cov‐ er or seal components. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E .can be used with these bolts. gr. ♦ Place removed parts on a clean surface. Use plastic sheeting and paper. Cover parts to pre‐ vent soiling.Golf Variant 2007 ➤ .2 Gearbox Always make sure that no dirt can enter an »open« gearbox. ensure that dowel sleeves be‐ tween the engine and gearbox are correctly located.and/or oil pump can lead to gearbox failure.Technical data ht rig py Co t. 2 Rep.G 1783. ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit 1. Use lint-free cloths only! ♦ Install only clean parts. . es. 4 O-rings. ♦ Before installing a radial oil seal. change the oil and adjust the oil level at the same time ⇒ page 90 .Edition 07.Gearbox oil cooler ⇒ page 51 5 . General repair notes 3 .Filter ⇒ page 90 ❑ ⇒ page 4 AG.and outer cir‐ cumference with dual clutch gearbox oil.Multi-clutch ⇒ page 15 AG.⇒ page 31 7 .Cover (end cover) for multiclutch agen lksw Vo by rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en r fo ng 9 . Jetta 2005 ➤ . Other lubricants will cause problems in function. The oil can be drained via the inspection plug 4 .Mechatronic unit for dual clutch gearbox -J743⇒ page 31 6 . in part or in wh ole.Drain plug ❑ ⇒ page 4 ❑ Plug was discontinued as of September 2004. cial p is n mer m ot p o c erm or e t a itte v i r d p un le 3 . 1. is or nte eo ra c ility ab y li an pt ce urposes. coat sealing lips and area between these with sealing grease -G 052 128. ♦ Open side of radial oil seal faces oil. ♦ Only use dual clutch gearbox oil.Golf Variant 2007 ➤ . seals and gaskets.2010 1. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E .and oil temperature sender in multi-plate clutch G509. Volkswagen AG d agen oes ❑ Notes on filter ksw change not l o gu yV b ara ⇒ page 4 ed th 2 . C op yi 1.Inspection plug au ss ⇒ page 90 ❑ Near pendulum support. ht rig py Co t.Oil pump ⇒ page 54 8 .3 Overview 1 . ♦ After installation. Prote cted by c o py rig ht .Gearbox input speed send‐ er -G182. Golf Variant 2010 ➤ . seals and gaskets ♦ Renew O-rings. wage Please also refer to ⇒ page 4 for important information about olks V y assessing the oil. in part or in wh ole. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . The oil performs many tasks.Golf Variant 2007 ➤ . cial p is n mer m ot p o c erm or e t a itte v i r d p Caution un le a ss n AG.Technical data AG. Oil stores and transports heat and reduces noise. ut Use caution when handling oil. In the next mo‐ ment. The oil is available as a Genuine part. The oil quality is of decisive importance for the function of the gearbox. ♦ Leaking covers in the mechatronic unit. Volkswagen AG do es n ot g ua ran tee or ac ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en 1. Do not mix additives in oil.Edition 07.5. Jetta 2005 ➤ . The oil filter does not have to be changed as a matter of course. 4 Rep. Dispose of used oil properly.000 kilometre service interval has been reached. it seals the spool valves and aids the synchro-rings during gear changes.»Yes or no?« r fo ng . In addition. ♦ The clutch is burnt out or has a mechanical defect.has been renewed. Consider that the oil just transported miniscule particles of metal from the differential to both filters. it provides the pressure necessary for the gear actuators to do their job. One drop of oil will contaminate 600 litres of water. Therefore the Genuine part number for it can be found in the ⇒ Electronic parts catalogue „ETKA“ . ♦ Metal particles have been found in the oil. ht rig py Co t.with oil temperature sender in multi-plate clutch -G509. agen lksw Vo by 1. the multi-clutch or oil pump have been renewed. This oil ensured that the film of lubricant on the flanks of the teeth does not tear. C op yi To maintain this ability. db e ris ho Oil which has been drained out cannot be filled again. Do not fill any other oil. Dual clutch gearbox oil meets very exacting requirements. the filter on the gearbox should be re‐ newed together with the oil in the maintenance service.2 Oil filter change . gr.5 Dual clutch gearbox oil Shake before opening.1 Tasks of the oil The oil does more than just »lubricate« the gearbox. Do not change the filter if: ♦ The gearbox oil cooler or its O-rings have been renewed and no coolant has got into the oil.2010 1. ♦ Coolant has got into the oil. ♦ The oil seal for the flange or stub shaft has been renewed. ♦ The gearbox input speed sender -G182. Golf Variant 2010 ➤ . The filter must be changed if: ♦ The 60.5. Prote cted by c o py rig ht . ♦ The oil seal for the selector shaft has been renewed.00 . urposes. C op yi 1. c o p yri gh t.. torque setting 3 Nm) is located behind the plug. Prote cted by 1. gearboxes were constructed with 2 plugs. Jetta 2005 ➤ . ♦ Threads of bolts secured with locking fluid must be cleaned with a wire brush. ht rig py Co t. and oil could be drained and the level checked with only one plug -A-.Golf Variant 2007 ➤ . rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en 1. Golf Variant 2010 ➤ . Its length deter‐ mines the oil level in the gearbox. A plastic overflow tube (with 8 mm hexagon socket head bolt.Edition 07. Otherwise there is a danger of bolts shearing when subsequently being removed. ♦ Torque settings are specified for unoiled bolts and nuts. »Just« topping up the oil doesn't repair any defects.2010 1. guar d a e tho if it has run out of the gearbox. ♦ All threaded holes into which self-locking bolts are to be screwed must be cleaned of residual locking fluid using a thread chaser. Then insert bolts with locking fluid -AMV 185 101 A1.4 Oil drain and inspection plug -Ar fo ng To gearbox manufacture date „20 September 2004“. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E .6 Nuts and bolts ♦ Loosen and tighten securing bolts and nuts for covers and housings diagonally. General repair notes 5 . The second plug was then discontinued. Only then add fresh oil to achieve the »correct« oil level ⇒ page 90 . It doesn't help to find the fault. in part or in wh ole.5. but it gives one an unjustified feeling of security. ag oil does here ⇒ page You can read about all the things that ksw not Vol y There is one thing it cannot bdo: »disappear without a trace«. ♦ Always renew self-locking bolts and nuts. agen lksw Vo by AG.3 Oil and fault finding via oil level check olkswagen AG en AG.5. V Oil and fault finding via oil level check does 4 . check where the oil has escaped from the gearbox. cial p is n mer m ot p o c erm or e t a itte v i r d p un le ris Gearbox oily ss nte eo ra c ility ab y li an pt ce – First. Re‐ pair this leak first. Oil can only go missing au urposes. gu y b a i or electrical components. Golf Variant 2010 ➤ .Edition 07. This charge can disturb the function . for example a water pipe or lifting platform.2010 1. d se ran tee or ac ility ab y li an pt ce urposes. Volkswagen AG en AG of electrical components of the gearbox and of the selector mech‐ does ag w s k not Vol anism.Golf Variant 2007 ➤ . Jetta 2011 ➤ 6-speed dual clutch gearbox 02E .00 . agen lksw Vo by AG. touch an – Before beginning workthon u a earthed object. Prote cted by c o p yri gh t. cial p is n mer m ot p o c erm or e t a itte v i r d p un le rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en r fo ng 6 Rep.Technical data ht rig py Co t. ss Please do not grip plug contacts directly. gr. Jetta 2005 ➤ . C op yi . This is due to the electrostatic charge of the human body. in part or in wh ole.7 Electrical components You have probably at some time received an electrical shock when touching a metal object. ho t u sa es. work e r and expenses. first check ⇒ Technical Solutions to see if a solution to the problem is listed. AG. in this case ⇒ page 9 . 2. For example.2010 2 Fault finding Before making repairs. Make use of this possibility! This will saveistime. Fault finding do c um en 7 . Fault finding is performed with the vehicle diagnostic tester . determine the cause of the fault as pre‐ cisely as possible with the aid of „guided fault finding“. Golf Variant 2010 ➤ . Finding a fault without a thoughtout search would be -magic.Edition 07. When searching for a fault. This soft‐ ware is able to execute. This must also be considered when looking for faults. in part or in w l purpos hole ercia . Therefore. – Be aware »what sort of problem« is on hand and which means of fault finding are available. keep the bus system in mind.2 Useful information about the „behaviour of the control unit in the event of a gear‐ box fault“ agen lksw Vo by But no electronics can do something for which it was not de‐ signed. Volkswagen AG do es n wage ot g ua ran tee or ac ility ab y li an pt ce ♦ When calling your importer or the ⇒ TSC. Prote cted by c o p yri gh t. lks ♦ It is also possible to contact your ⇒ TSC or the importeryin Voyour b d country. is n m ot p om c r erm o e t a itte riv du p or nl f e g n s in other control ♦ It can also be helpful to know the faults entered units. So it is just not possible to identify electronically. n AG. This control unit »has everything« that a modern gearbox electronics »has to offer«. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . Always interrogate all control units. for ht rig py Co t. 2. monitor and control electronic functions in milliseconds. have a diagnosis log on hand. C op yi The control unit works with highly developed software.Golf Variant 2007 ➤ .and does not lead to success. ♦ It must also be clear that it is not necessary to look for faults which have already been found and are known to others. Jetta 2005 ➤ . rrectness of i t to the co nform spec at i h re o n wit in t his 2.1 General notes on fault finding Planning fault finding Try to plan the fault search sensibly. It may be possible to notice changes in driving behaviour. For example. Some possible causes may be the towing of a trailer with too great a load or retrofitted compo‐ nents at the front of the vehicle leading to »insufficient air cooling«. 4- 2. Volkswagen AG d agen o es.will begin blinking. the control unit prevents 1st gear from being engaged to prevent damage to the gearbox. in part or in w l purpos hole ercia .3. r te o iva r rp fo g n pe rm itte d example. But it is possible to detect the effects of »insufficient oil«. First a fault in „gear monitoring“ will be detected and finally the control unit will react by opening both clutches (no power transfer).flashes. c o p yri gh t. It might happen that the source of a fault is not discovered with Guided fault finding .es n Golf Variant 2007 ➤ .2010 nt se AG. Prote cted by ht rig py Co t.1 Special notes on fault finding Selector lever position display . The gear will not be engaged until the vehicle has stopped moving. Individual selector lever positions blink in the selector lever position display -Y5.. Reversing not pos‐ sible.. is n m ot com You should be aware of this when looking for faults and working with Volkswagen testers.w Jetta 2005 ➤ . Behaviour of the control unit in the event of a fault If a component in the gearbox malfunctions. C op yi . the letter „D“ in selector lever position display -Y5. For example: the gearbox oil temperature is too high. Changes in driving and gearshift behaviour are clearly apparent. Golf Variant 2010V➤ . gr. there are 4 fault responses: 1The fault is so minor that travel may be continued with a substitute program and driving safety will be preserved. A »major fault« has occurred. The driver is being warned that it is not possible to select this gear at the moment. If you should want to try this out. If „D“ is selected in this situation. a great deal has been done to protect the gearbox in case of a malfunction (safety func‐ tions). driving in reverse: the lever is in „R“ and the vehicle is trav‐ elling backwards. 8 Rep.no „R“ Simultaneous illumination of all selector lever position display segments indicates gearbox emergency running mode. Part of the gearbox has been switched off and the gearbox must be repaired. be careful. The display indicates the selector lever position as usual. if it is necessary.Technical data agen lksw Vo by AG. The selected selector lever position is not recognisable. Consequently. The ve‐ hicle cannot reverse. where oil is leaking from housing. the fault is saved and a substitute program is started. when a fault occurs.00 .is completely illumi‐ nated and is blinking. The selected range display -Y5. The driver will not be warned via the selector lever position dis‐ play -Y5. Jetta 2011 ➤ ot olks gu by ara d 6-speed dual clutch gearbox 02E -riEdition 07. un le ho ut sa the sgearbox ee or ac ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s do c um en 2- 3- The selector lever position display -Y5.3 2. Because the gearbox must be protected as far as possible. the control unit re‐ sponds with a substitute function. The selected selector lever position is recognisable or is highlighted. In this situation. As well as the more advanced software. 6 If there are faults »not caused by the gearbox« For example. Golf Variant 2010 ➤ . The -arrow.Golf Variant 2007 ➤ . then the gearbox control unit is not likely to be »faulty«.3. Anything else is »expensive fun« which will not help. The entry means only that the gearbox (and possibly other control units) are expecting a signal via the bus. 2.be removed without further consideration. Jetta 2005 ➤ . Guided fault finding will locate the sources of many faults. agen lksw Vo by AG. ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s 2. 2.4 No faults have been saved In this case. pe rm itte d un le .2 Touch function does not work .points to the Bowden cable adjusting screw.3.may go lost.3. In particular.2010 2. The fault in this example indicates problems in the ⇒ ABS. Experience shows that »faults« attributed to the gearbox often are caused by other com‐ ponents or assemblies.3. Fault finding ht rig py Co t.must never be reused. C op yi 9 . The VW testers offer Guided fault finding . 2. if the fault „ABS signal missing“ is saved in the gearbox memory and additionally another control unit reports „ABS signal missing“.5 Faults have been saved es. Volkswagen AG gen AG does swa k not l o It has occurred in the past that poor shifting behaviour was due gu yV b ara d sort to insufficient air intake of the engine.3. Prote cted by c o py rig ht .Edition 07. in part or in w l purpos hole ercia . Properly used. clip -B. but does not receive it. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . Don't make the same e nte is r o eo h of mistakes.possibly insufficient fluid First click here ⇒ page 4 . ut ra a c s s Only after such faults have been excluded can one work mean‐ ingfully with the VW tester. In this case. under no circumstances should the me‐ chatronic unit for dual clutch gearbox -J743. it is more likely that the ⇒ ABS control unit has a problem. r te o iva r rp fo g n do c um en 2. In such a case. Due to the loss of its »own tension«. Top up fluid only when it has been ascertained that fluid has es‐ caped. the solution depends on you. this clip -B.3 »Power transfer« inadequate . is n m ot com First consider what the saved faults indicate.no gear change Check securing clip on cable support bracket of selector lever cable on top of gearbox. 10 May 2002 14 . gearbox code is also located on the top of the gearbox near the selector lever cable -arrows-. is n m ot p om c r erm o e t a itte riv du p or nl f e g n Example -arrow-: k Vol by d e ris tho u a ss not gu ara nte eo ra c ility ab y li an pt ce GKF . if the installed gearbox does not match the one indicated on the sticker or if the installed gearbox cannot be definitively identified: read gearbox code off gearbox.00 . 3. Prote cted by c o p yri gh t . agen lksw Vo by AG.Edition gen07.Golf Variant 2007 ➤ .2010 oes swa 3 Gearbox identification es.Serial number do c um en On some gearboxes. Volkswagen AG d 6-speed dual clutch gearbox 02E . C op yi . The gearbox code is also included on the vehicle data stickers.2 . If there is no vehicle data sticker.1 Reading gearbox code letters The code appears on every gearbox in at least two places.05.Gearbox code letters 10. 10 Rep. Jetta 2005 ➤ . Reading code directly on gearbox ⇒ page 10 . Golf Variant 2010 ➤ . gr.Technical data ht rig py Co t. Jetta 2011 ➤ AG.Factory code 14 15 . in part or in w l purpos hole ercia .Time rrectness of i t to the co nform spec at i h re o n wit in t his 001 . 23 . Removing and installing battery . gr. the se‐ lector lever cable must be adjusted ⇒ page 70 . 27 . In the process. the gearbox code may also be found under the bracket of the left assembly mounting. If it is not legible or is»upside down«. If it is lowered further. Golf Variant 2010 ➤ . in part or in wh ole. the engine and gearbox must be supported. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . it is important to lower the engine and gearbox only enough so that the bracket can be pushed back. gr. agen lksw Vo by AG. C op yi 3.for the lefthand assembly mounting must be removed. Bracket -A. ht rig py Co t. – Remove all bolts -1.for bracket -A-.and -2. Prote cted by c o p yri gh t.Edition 07.and support engine with gear‐ box. 24 . Do not raise. Following assembly. – Then lower engine and gearbox slightly using spindles of sup‐ port bracket -10 . ♦ Vehicles with petrol engines ⇒ Rep.222 A. Bolts must be renewed. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en Set up support bracket -10 . the ⇒ pendulum support will be damaged.⇒ Rep. Battery. Removing and installing air filter ♦ Vehicles with diesel engines ⇒ Rep. Jetta 2005 ➤ .Golf Variant 2007 ➤ .until bracket can be removed. Gearbox identification 11 . r fo ng un le AG. Removing and installing air filter – Remove battery and battery tray -arrows. cial p is n mer m ot p o c erm or e t a itte v i r d p To see the code directly on the gearbox behind the bracket. gr. urposes. Perform the following steps: – Remove complete air filter housing.2010 Once on top of the gearbox close to the selector lever cable -two arrows-.222 A. 2 turns of the spindle will be sufficient to remove the bracket -arrow-. gr. es. After gearbox code has been read. observe all the following instructions. – Renew all bolts on left assembly mounting. assembly can be performed in the reverse order. see ⇒ page 87 . C op yi . 12 ht rig py Co t. – Always adjust selector lever cable after installing bracket ⇒ page 70 . is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng AG. – For a description of proper installation of bracket -A.Edition 07.and -2-. in part or in w l purpos hole ercia . Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit thi sd o cu m en Rep.00 .2010 In most cases.on gear‐ box with bolts -1. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . Jetta 2005 ➤ .Technical data AG. – First screw in all bolts by hand. agen lksw Vo by Prote cted by c o p yri gh t.Golf Variant 2007 ➤ . Golf Variant 2010 ➤ . – Nevertheless. GPU. HLH. Golf Variant 2010 ►. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s HVV GAY. always refer to the gearbox code. KPQ Installed in ility ab y li an pt ce es. HQN.100. MSX HLE. HUT. HUS. HLF. HXU. Jetta 2005 ►. HQF. 2. HXW. Jetta 2005 ➤ . Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . HBP. Prote cted by c o py rig ht . HJQ. GYQ. 125 kW TFSI 125 kW kW TDI TSI Golf Variant 2007 ►. HBQ.2010 4 4. in part or in w l purpos hole ercia . GYR.engine allocation Identification code If Genuine parts are required for a repair.0 l .9 l . HQH.0 l .engine allocation ht rig py Co t. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng rrectness of i t to the co nf o r m spec atio h re n in wit thi sd o cu m en 4. HRW.Edition 07. LQV. MSV 1.1 Code .Golf Variant 2007 ➤ . GPW. Dual clutch gearbox (⇒ DSG®) 02E »front-wheel drive« GKF.4 l . Jetta 2011 ► AG. GYM. Code . GYN.103 1. C op yi 13 . HBQ. HTB. HQQ. HFQ.77 kW 2. agen lksw Vo by AG. HQL. GPV. Golf Variant 2010 ➤ .147 and TDI 103. LTE. KPS. HXS. is n m ot p om c r erm o e t a itte riv du p or nl f e g n 6. Volkswagen AG d gearbox construction agen oes ksw not l o V gu y Change quantity in custom‐ about 5. agen lksw Vo by AG. Jetta 2005 ➤ .2 l b ara d nte ise er service r o eo h t u ra a Lubricant Dual clutch gearbox oil c s s ility ab y li an pt ce rrectness of i t to the co nform spec at i h re o n wit in t his do c um en 14 Rep. in part or in w l purpos hole ercia . gr.Edition 07. Therefore the part number for it can be found in the ⇒ Electronic parts catalogue „ETKA“ .Golf Variant 2007 ➤ .Technical data ht rig py Co t.00 .2 l depending on vehicle and date of AG. C op yi . Prote cted by c o p yri gh t.9 … 7. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . es. Golf Variant 2010 ➤ .2010 5 Capacity Capacity Dual clutch gearbox 02E Initial filling in factory The oil is available as a part. Prote cted by c o p yri gh t . the meth‐ od of assembling and installing the clutch in the gearbox housing is shown here. If parts are rotated relative to each other during assembly. s k not l o V gu y so the term „multi-clutch“ is more appropriate. Notes on clutch 15 . In this case. Therefore. urposes. imbalances develop which are detrimental to ease of shifting and service life. The smaller inner „C 2“ (clutch 2) selects gears »2«.Golf Variant 2007 ➤ . Clutches of ⇒ DSG®s always contain at least 2 »clutches«.making risit a ⇒ wet clutch. cial p is n mer m ot p o c erm or e t a itte v i r d p When carefully considered. you should carefully refer to this de‐ scription ⇒ page 16 . The outer. Jetta 2005 ➤ . C op yi 1. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . the term »clutch« is n not exactly cor‐ . agen lksw Vo by AG. »4« and »6«.2010 30 – 1 Clutch Notes on clutch The assembly of the multi-clutch requires special care because all components have been balanced together during manufac‐ ture. Therefore. un le ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en r fo ng ht rig py Co t.Edition 07. the b ara d e nte clutch has 2 sets of plates . To avoid the risk of parts rotating relative to each other. »3« and »5«. o eo h t u larger set of plates is called „C 1“ (clutch 1). Golf Variant 2010 ➤ . genuine clutches are supplied with a built-in retaining ring. in part or in wh ole. The „C 1“ selects ra a c s s reverse gear and gears »1«. Volkswag en AG ge AG does wa rect. 2010 2 Removing and installing clutch It is currently possible to see a film demonstrating how the clutch is removed.notes on dual clutch gearbox DSG". is n m ot com pe rm itte d – Secure gearbox to assembly stand ⇒ page 89 . Volkswagen iTV. – Remove this oil pipe. C op yi r te o iva r rp fo g n do c um en 16 Rep. To gearbox manufacture date „20 September 2004“. gen AG en AG. gearboxes were constructed with 2 plugs. the last two levels will be approxi‐ mately "Engine and Gearbox" and "All models . Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . After the retaining ring has been removed. Prote cted by c o py rig ht . Motor/Getriebe.Edition 07. Cover and retaining ring must al‐ ways be renewed. ho ut t gu ara nte eo ra c ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s – Drain oil. Torque setting: 45 Nm ht rig py Co t. V does wagto should happen. A plastic overflow tube (with 8 mm hexagon socket head bolt.1 Removing clutch cover (end cover) Perform the following steps: The cover seals the gearbox. iTV API Online. – Drain oil. The second plug was then discontinued. The cover is held in place by a re‐ taining ring. the cover can be levered out of its seat. The cover over the clutch must be removed before the clutch can be removed ⇒ page 16 .Golf Variant 2007 ➤ . torque setting 3 Nm) is located in this hole.Clutch agen lksw Vo by AG.Hinweise zum Direkt-Schalt-Getriebe DSG . . The path to the film is ⇒ Volkswagen ServiceNet. gr. VW/Audi TV. – Screw in overflow pipe with 3 Nm torque. and oil could be drained and the level checked with only one plug -A-.30 . Golf Variant 2010 ➤ . – Install drain plug -A. Alle Modelle . Never install a new cover with a hammer and never oil the centre seal or touch it with a hand! if this olkswaHowever. un le a – Remove gearbox ss ⇒ page 76 . ris V by es. the video was available only in German. At the time of publication. in part or in w l purpos hole ercia . Jetta 2005 ➤ . the cover is certain leak! no olks ed The gearbox must be removed for work on cover. 2.with new seal. If and when it appears in English. Its length determines the oil level in the gearbox. 2. Golf Variant 2010 ➤ . Jetta 2005 ➤ .2010 – Remove the filter if necessary. s s gen or Often. do c um en – Following repair work.Golf Variant 2007 ➤ . Volkswagen AG d oes not gu ara nte ise r o eo h The notes on the oil filter change ⇒ page 4 can help you in reach‐ t u ra a c ing this decision. is n m ot p om c r erm o e t a itte riv du p or nl f e g n rrectness of i t to the co nform spec at i h re o n wit in t his – Insert new filter with shoulder downwards and tighten cover to 20 Nm. it is not necessary to change filter again when filling oil. – Remove retaining ring from cover. y db ility ab y li an pt ce es. C op yi 17 . Removing and installing clutch ht rig py Co t. in part or in w l purpos hole ercia .Edition 07. Install only a »new« cover ⇒ page 18 . Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . Remove cover. doubts arise as to whether the filter must be lk renewed swa Vo not. agen lksw Vo by AG. AG. Prote cted by c o p yri gh t. Cover can be levered out with a screwdriver. Leaks will result. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . – Only handle cover as shown in the picture! r fo ng Special tools and workshop equipment required 18 Rep. ♦ Covers supplied without a bush ⇒ page 18 . Perform the following steps: urposes. ♦ Covers supplied with a white bush ⇒ page 20 . Jetta 2005 ➤ .2 Installing clutch cover (end cover) There are 2 types of cover.Edition 07. in part or in wh ole. oiled or brought into contact with other materials. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en Cover and retaining ring must always be renewed. C op yi . agen lksw Vo by AG. gr. Prote cted by c o p yri gh t.Golf Variant 2007 ➤ . Golf Variant 2010 ➤ .1 Installing covers supplied without bush un le AG.Clutch ht rig py Co t.30 .2010 2. Never install a new cover with a hammer and never oil the centre seal or touch it with a hand! Caution Do not grasp new cover in centre hole.2. cial p is n mer m ot p o c erm or e t a itte v i r d p 2. The hole of the cover must not be touched. Edition 07. There must be no stickers on the inside of the cover. agen lksw Vo by AG. Prote cted by c o p yri gh t. The centre seal of the new cover must now be »preformed«: AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s sleeve.Golf Variant 2007 ➤ . Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . New cover must be free of oil and dry around centre seal! – If necessary. Removing and installing clutch ht rig py Co t. – Set sleeve on a flat surface. ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit thi sd o cu m en 2. C op yi 19 . is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng – Guide cover horizontally and evenly over entire will bring the sealing lip into installation position. clean end of clutch shaft. Do not use a scratched sleeve. This s – Now remove sleeve upwards out of cover and set sleeve on end of clutch shaft es. remove them carefully! Moisten only the outer edge of the seal with DSG oil. Golf Variant 2010 ➤ . in part or in w l purpos hole ercia . – If any stickers are present. Jetta 2005 ➤ .2010 ♦ Assembly sleeve -T10302- Caution Clean assembly sleeve before using. Caution Work carefully. un le rrectness of i t to the co nform spec a t i h re o n in wit thi s 2.Clutch agen lksw Vo by .2010 – Guide cover horizontally over sleeve and press evenly onto its seat. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . The hole of the cover must not be touched. Any sort of blow to the cover is certain to cause leaks. AG. Never install a new cover with a hammer and never oil the centre seal or touch it with a hand! Caution ht rig py Co t. pe rm itte d It is possible to lever cover carefully into its seat with a screwdriver -arrow. gr.2 Installing covers supplied with bush r te o iva r rp fo g n Perform the following steps: Cover and retaining ring must always be renewed.Edition 07. in part or in w l purpos hole ercia . Leaks will result. Prote cted by c o p yri gh t. is n m ot com – Install new retaining ring.2. Golf Variant 2010 ➤ . Do not remove bush! 20 Rep. AG. C op yi do c um en Do not grasp new cover in centre hole. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce es. Jetta 2005 ➤ . oiled or brought into contact with other materials.30 .Golf Variant 2007 ➤ .until »new« retaining ring can be installed. It is possible to lever cover carefully into its seat with a screwdriver -arrow. remove them carefully! Moisten only the outer edge of the seal with DSG oil. Any sort of blow to the cover is certain to cause leaks.Edition 07. gearbox must be securely attached to an assembly stand in vertical position. agen lksw Vo by c o p yri gh t . There must be no stickers on the inside of the cover. – If any stickers are present. – Install new retaining ring. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . C op yi AG.Golf Variant 2007 ➤ . – Insert cover with bush. clean end of clutch shaft. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en 2. ht rig py Co t. – Remove clutch cover (end cover) ⇒ page 16 .2010 New cover must be free of oil and dry around centre seal! – If necessary. Caution Work carefully. Jetta 2005 ➤ . Prote cted by 2. cial p is n mer m ot p o c erm or e t a itte v i r d p – Do not remove bush until retaining ring is installed. Golf Variant 2010 ➤ . un le n AG.3 Removing clutch Perform the following steps: r fo ng To remove or install clutch. Removing and installing clutch 21 .until »new« retaining ring can be installed. in part or in wh ole. urposes. Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed dual clutch gearbox 02E - Edition 07.2010 – Remove retaining ring from clutch cover. – Remove cover from clutch. – Remove retaining ring -arrow-. Note: this retaining ring must be measured again during installa‐ tion and renewed. Caution Carefully remove clutch. Ensure that end cover or other parts of clutch do not fall out. Therefore, do not turn over clutch under any circumstances! But if this should happen ⇒ page 29 . – Remove clutch. AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n rrectness of i t to the co nform spec at i h re o n wit in t his – Remove pump shaft -A-. – Pump shaft is not inserted until after new clutch is installed. Set shaft aside until then. do c um en Multi-clutch as replacement part 22 Rep. gr.30 - Clutch ht rig py Co t. 2.4 Preparing installation of multi-clutch agen lksw Vo by Prote cted by c o p yri gh t. C op yi AG. Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed dual clutch gearbox 02E - Edition 07.2010 1 - Multi-clutch ❑ The cover of a new clutch is secured with a retaining ring. 2 - Retaining rings ❑ Qty. 10 ❑ Rings have different »thicknesses«. They are sized in 0.1 mm in‐ crements. ❑ Refer to instructions in ⇒ page 24 . 3 - Cover (end cover) ❑ Ensure that inner seal‐ ing lip is not damaged ⇒ page 18 . Manufactur‐ AG. Volkswagen AG d er inserts a bush to pro‐ agen oes ksw not l tect sealing lip. Please o gu yV b ara d in cover. leave this bush e n s 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 t 4 - Retaining ring au ss ❑ For cover. ri ho tee or ac ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit – When removing clutch from packing, press on clutch cover. This is to prevent the clutch cover and the plate carriers beneath it from sliding out of the inner plates. ht rig py Co t. Prote cted by c o py rig ht . C op yi thi sd o cu m en agen lksw Vo by AG. 2. Removing and installing clutch 23 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed dual clutch gearbox 02E - Edition 07.2010 – Make sure that the 4 -piston rings- are correctly located. gen AG AG. other«. gen Ring gaps should not be »over each does swa Volkswa – Turn es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n k Vol by dThey rings once. must e ris ho t au ss ua move freely and must not rbind. an not g tee or ac ility ab y li an pt ce rrectness of i t to the co nform spec at i h re o n wit in t his Important! Position of clutch cover – Look to see whether there is a marking on clutch -arrow-. – If there is no mark, make a coloured mark. Later the »lug« of the cover must be placed at the marked spot. Set down clutch so that it cannot tip over. The clutch is now ready for installation ⇒ page 24 . do c um en 2.5 Installing and adjusting clutch Caution Avoid removing or lifting plate carriers. Not even a little bit! The plates could turn. Perform the following steps: • • • • • Gearbox must be turned »vertical in assembly bracket«. Only this way is it possible later to adjust axial play of the clutch without error. It is essential that the gearbox be securely clamped in support clamp -VW 313- or engine and gearbox support -VAS 6095⇒ page 89 . It must not be turned. Inside the clutch, the large plate carrier goes through all plates. It must not slip out of the lowest plates. The pump shaft of the oil pump is removed. Do not install corrugated retaining rings. Special tools and workshop equipment required 24 Rep. gr.30 - Clutch ht rig py Co t. agen lksw Vo by AG. Prote cted by c o py rig ht . C op yi ht rig py Co t.on seat of cover. Removing and installing clutch agen lksw Vo by AG. Do not remove the pin until instructed to do so. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s – The -retaining pin. Golf Variant 2010 ➤ .without letting it fall in. un le – Then insert -clutch. Clutch is inserted with cover as it was when packaged.should be held by a second mechanic in the process. But not yet. is n m ot com pe rm itte d Do not mount on clutch.Edition 07. Prote cted by c o py rig ht . in part or in w l purpos hole ercia . -Retaining pin.remains inserted until all further work has been »completed«. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . 25 . Jetta 2005 ➤ . AG. es. C op yi r te o iva r rp fo g n do c um en 2.2010 ♦ Retaining pin -T10303- – First set -retaining pin.Golf Variant 2007 ➤ . Golf Variant 2010 ➤ . agen lksw Vo by AG. – Set -tip of dial gauge.on input shaft.Clutch ht rig py Co t.remains in! pe rm itte d – Select 2 mm retaining ring from among the rings supplied and install it temporarily -arrow-.from clutch and lay it to side.to 0 with preload.Edition 07. Prote cted by c o p yri gh t. Jetta 2005 ➤ . is n m ot com Before this ring is removed again. Not even a little bit! The plates could turn. – Set -dial gauge.remains in! r te o iva r rp fo g n do c um en 26 Rep.Golf Variant 2007 ➤ . C op yi . gr. Caution Avoid removing or lifting plate carriers.to gearbox flange. un le rrectness of i t to the co nform spec a t i h re o n in wit thi s – Screw universal dial gauge -VW 387. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s ility ab y li an pt ce es. in part or in w l purpos hole ercia .2010 – Carefully remove clutch cover -arrow. First measurement • Retaining pin -T10303. Second measurement • Retaining pin -T10303. AG. – Raise clutch to stop and note result of measurement.30 . 2 measurements must be made. Jetta 2005 ➤ .Golf Variant 2007 ➤ . Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce The remaining 9 retaining rings are in increments of 0.2010 – Set tip of dial gauge -on hub of large plate carrier-. AG. – Raise clutch to stop again and also note this result. – Measure all rings and determine which ring is closest to your result. Tip must not sit on retaining ring. Golf Variant 2010 ➤ . C op yi 27 . Now it can be determined which of the remaining 9 rings will ulti‐ mately be installed: – Use this formula: Second measurement minus first measurement plus 1. es. Prote cted by c o p yri gh t. – Dispose of all remaining rings and the 2 mm thick ring. – Set -dial gauge. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E .to 0 with preload again. Retaining rings are only allowed to be installed once. 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 rrectness of i t to the co nf o r m spec atio h re n in wit – Insert -pump shaft-. agen lksw Vo by AG.1 millimetre. – Remove 2 mm thick ring and install calculated ring.Edition 07. thi sd o cu m en 2.85 mm = thickness of ring to be installed – Please make a note of this result. Removing and installing clutch ht rig py Co t. Jetta 2005 ➤ . Prote cted by c o p yri gh t. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng rrectness of i t to the co nf o r m spec atio h re n in wit thi sd o cu m en 28 Rep. After installing gearbox – Conduct basic adjustment of mechatronic unit for dual clutch gearbox -J743.. C op yi . in part or in w l purpos hole ercia .. – Install cover (end cover) ⇒ page 18 .30 . Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce es. gr. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E .2010 – Install clutch cover so that lug aligns with marking.Golf Variant 2007 ➤ . AG. agen lksw Vo by AG. This concludes the installation and the clutch is correctly adjusted.Edition 07.Clutch ht rig py Co t. Golf Variant 2010 ➤ . – Then remove retaining pin -T10303. agen lksw Vo by AG.Golf Variant 2007 ➤ . Removing and installing clutch ht rig py Co t. imbalances result which reduce ease of shifting and service life. Jetta 2005 ➤ . in part or in w l purpos hole ercia . Prote cted by c o p yri gh t. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . If parts of clutch have slipped out or plate carriers have been lifted: The large plate carrier »and if necessary. also the small one« can be threaded into all inner plates by hand with gentle turning move‐ ments. Especially the clutch cover should always be installed in the same position as was the case in the »delivery« of the new clutch ⇒ page 24 . Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s r te o iva r rp fo g n do c um en Special care The assembly of the multi-clutch requires special care because all components have been balanced together during manufac‐ ture. C op yi 29 . is n m ot com pe rm itte d un le AG. Golf Variant 2010 ➤ . 2.Edition 07.2010 es. If parts are turned relative to each other. Large plate carrier ❑ Do not remove Caution AG. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . Golf Variant 2010 ➤ .Clutch agen lksw Vo by AG.Edition 07. in part or in w l purpos hole ercia . is n m ot com 4 . it should be re‐ newed with a new. Not even a little bit! The plates could turn. ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s r te o iva r rp fo g n do c um en 30 Rep. C op yi .Thrust washer 7 . 4 3 . equally thick ring 8 . 4 6 . gr.2010 1 . 4 5 .Inner plate ❑ Qty. 10 .Outer plate ❑ Qty.Clutch cover pe rm itte d un le Avoid removing or lifting plate carrier.Retaining ring ❑ If retaining ring was re‐ moved to insert new plates.Golf Variant 2007 ➤ .30 .Retaining ring ❑ This ring must be re‐ measured each time the clutch is installed 9 . Jetta 2005 ➤ .Retaining ring ❑ Always renew ❑ Do not install corrugated retaining rings ht rig py Co t.Multi-clutch housing 2 . Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s es. Prote cted by c o p yri gh t.Seal ❑ Qty. Volkswagen AG d agen oes ksw not sender in multi-plate clutch l o V gu y b ara G509d e nte is r o eo h ❑ Before sender can be ut ra a c s removed. es. see ⇒ page 60 Selector mechanism pe rm itte d un le rrectness of i t to the co nform spec a t i h re o n in wit thi s r te o iva r rp fo g n do c um en Removing and installing with gearbox removed ⇒ page 40 . is n m ot com ility ab y li an pt ce 3 .2010 34 – 1 Controls. C op yi 31 .Edition 07. housing Electrical and electronic components for the dual clutch gearbox and their locations There are electrical and electronic components in the gearbox.Mechatronic unit for dual clutch gearbox -J743❑ Behind »large« sheet metal cover ❑ Removing and installing with gearbox installed ⇒ page 31 ❑ Removing and installing with gearbox removed ⇒ page 40 2 . ht rig py Co t.1 Removing and installing mechatronic unit for dual clutch gearbox -J743(gearbox installed) AG. Prote cted by c o py rig ht . Special tools and workshop equipment required 1.Selector lever -E313❑ For information about selector lever. Electrical and electronic components for the dual clutch gearbox and their locations agen lksw Vo by 1.and the selec‐ tor lever lock solenoid -N110.are located on the selector lever. mechatronic s unit for dual clutch gear‐ box -J743. 1 .and oil temperature AG.Gearbox input speed send‐ er -G182. Golf Variant 2010 ➤ . Jetta 2005 ➤ .must be re‐ moved ⇒ page 31 .Golf Variant 2007 ➤ . Only the selector lever sensors control unit -J587. in part or in w l purpos hole ercia . Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . G 1331- ♦ Used oil collection and extraction unit -V.2010 ♦ Torque wrench -V. gr. Prote cted by c o py rig ht . 27 .34 . Please also refer to the notes on the oil filter change regarding »dirty oil« ⇒ page 4 .noise in‐ sulation . Assembly overview . 50 . exterior. – With ignition switched off. – Move selector lever to position „P“ position.A. – Remove noise insulation ⇒ General body repairs.1 Removing mechatronic unit (gearbox in‐ stalled) Perform the following steps: Always make sure that no dirt can enter an »open« gearbox. disconnect battery earth strap ⇒ Electrical system. 21 .4 l engines only – Move lock carrier to service position ⇒ Rep. The mechatronic unit can stick on the dowel pins when the gear‐ box is very warm. Rep. C op yi thi sd o cu m en 32 Rep. For 1.Golf Variant 2007 ➤ . Disconnecting and connecting battery . Then let the gearbox cool off.1.A. In particular.and/or oil pump can lead to gearbox failure. 50 . Jetta 2005 ➤ . Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce es.Edition 07. If present: – Remove connecting hose between charge air cooler and charge air pipe ⇒ Rep. dirt entering an »exposed« mechatronic unit for dual clutch gearbox -J743. Golf Variant 2010 ➤ . is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng rrectness of i t to the co nf o r m spec atio h re n in wit 1. gr. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . gr. in part or in w l purpos hole ercia . Lock carrier.G 1782AG.Controls. gr. housing agen lksw Vo by AG. . gr. service position . ht rig py Co t. Noise insulation. Rep. Removing and installing parts of charge air cooling . Prote cted by c o p yri gh t.0 litres of oil will run out. – Position used oil collection and extraction unit -V. A plastic overflow tube (with 8 mm hexagon socket head bolt. Golf Variant 2010 ➤ . Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . C op yi do c um en – Release mechatronic unit connector -1.2010 Continuation for all vehicles Note AG. Electrical and electronic components for the dual clutch gearbox and their locations agen lksw Vo by AG. – Remove this oil pipe. – Remove bolt -A.should remain under gearbox.G 1782. ht rig py Co t. – Raise lines near cover and tie.Golf Variant 2007 ➤ . torque setting 3 Nm) is located in this hole. Its length determines the oil level in the gearbox.from front of »large« gearbox cover. This will create enough space to remove the mechatronic unit. ♦ Depending on the vehicle.on front of gearbox.Edition 07. 1. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce It is possible that parts having nothing to do with the mechatronic unit must be removed. in part or in w l purpos hole ercia . Used oil collection and extraction unit -V. 33 . is n m ot p om c r erm o e t a itte riv du p or nl f e g n rrectness of i t to the co nform spec at i h re o n wit in t his – Remove electrical wiring and retainers -arrows. for exam‐ ple. 3 Nm.A. ♦ Fan support -arrow♦ Additional lines for air conditioner ♦ Charge air or air cooling pipes es.by turning and pull off connector. Note Connector is located close to starter -A. – Screw overflow tube back in. To gearbox manufacture date „20 September 2004“. Jetta 2005 ➤ . This depends on the vehicle's equipment.A.G 1782under gearbox.near pendulum support. About 5. these parts may include. gearboxes were constructed with 2 plugs. r te o iva r rp fo g n do c um en 34 Rep. AG. c o p yri gh t. – Remove cover and seal. gr. Golf Variant 2010 ➤ . in part or in w l purpos hole ercia . Jetta 2011 ➤ 6-speed dual clutch gearbox 02E .34 . is n m ot com pe rm itte d rrectness of i t to the co nform spec a t i h re o n in wit thi s The pendulum support can be removed to make space for re‐ moving the mechatronic unit. es. C op yi .of cover diagonally and remove. Jetta 2005 ➤ .Controls. cover seal must also be renewed. – Guide cover past starter bolt.Edition 07. Prote cted by ht rig py Co t. housing agen lksw Vo by Before touching mechatronic unit. This allows the gearbox to be »pushed back« a little. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s ility ab y li an pt ce ♦ Cover bolts always must be renewed.Golf Variant 2007 ➤ .2010 – Loosen bolts -arrows. Note un le AG. ♦ Likewise. touch an earthed object ⇒ page 6 . Jetta 2005 ➤ .Edition 07. does not need to be removed in order to remove or install the mechatronic unit. the sender must be renewed. Golf Variant 2007 ➤ .through -10. If this happens. cial p is n mer m ot p o c erm or e t a itte v i r d p – Only press onto locking mechanism with screwdriver -1-. cover for oil pump. the side cover has been removed in the 1.– – Do not lever it.in given order and re‐ move. next illustration. The fastener of the connector can break. ht rig py Co t. – Use screwdriver -2. Volkswagen AG d agen oes dual clutch gearbox 02E . un le ot g o yV ua db ra e ris Carefully release hconnector of gearbox input speed sender -ntee o t u G182. Prote cted by c o p yri gh t. – Remove line from retaining lugs -arrows-. Jetta 2011 ➤ AG. 35 . Electrical and electronic components for the dual clutch gearbox and their locations agen lksw Vo by AG. Golf Variant 2010 ➤ . in part or in wh ole.or ac sa using a small s screwdriver -1-.with oil temperature sender in multi-plate clutch -G509. Do not pull on line! – Pull off connector. ♦ For greater clarity. Be very careful.to loosen connector. Do not use screwdriver as a lever.2010 6-speed w s n lk ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en r fo ng – Loosen securing bolts -1. C op yi Note ♦ The side cover -A-. urposes. es. Prote cted by . C op yi AG. Lay mechatronic unit to side properly. Never lift mechatronic unit on »sender arm« or lay it on arm.34 .on back is no longer in gearbox housing. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . in part or in w l purpos hole ercia . Golf Variant 2010 ➤ .Controls. agen lksw Vo by c o p yri gh t . Jetta 2005 ➤ . gr. pay special attention to the »long« sender arm -B-.Golf Variant 2007 ➤ .2010 – Carefully pull mechatronic unit out of gearbox housing so that sender arm -B.Edition 07. housing ht rig py Co t. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s Caution r te o iva r rp fo g n do c um en 36 Rep. is n m ot com pe rm itte d un le n AG. When handling mechatronic unit.downwards. – Carefully swing mechatronic unit for dual clutch gearbox J743. C op yi 37 . is n m ot p om c r erm o e t a itte riv du p or nl f e g n AG. es. Golf Variant 2010 ➤ .2010 If »arm« is damaged. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce 1. Prote cted by c o p yri gh t. do c um en 1.1. touch an earthed object ⇒ page 6 . Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . Electrical and electronic components for the dual clutch gearbox and their locations ht rig py Co t.2 Installing mechatronic unit (gearbox in‐ stalled) rrectness of i t to the co nform spec at i h re o n wit in t his Perform the following steps: Before touching mechatronic unit. agen lksw Vo by AG. in part or in w l purpos hole ercia .Golf Variant 2007 ➤ .Edition 07. mechatronic unit must be renewed. Jetta 2005 ➤ . C op yi .Controls. Golf Variant 2010 ➤ . Note ♦ The side cover should not be removed in order to remove other parts ♦ The side cover is not shown in this illustration.Golf Variant 2007 ➤ . This is to make it clear how the »long arm« will be damaged if the mechatronic unit is canted. Prote cted by c o p yri gh t. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . in part or in w l purpos hole ercia .2010 If »arm« is damaged. – Carefully set mechatronic unit for dual clutch gearbox -J743in gearbox housing.Edition 07. Ensure that »sender arm« locates in its -fitting position-. This stops down pins from »jam‐ ming« during insertion. housing ht rig py Co t. Mechatronic unit for dual clutch gearbox -J743. mechatronic unit must be renewed. gr. is n m ot com pe rm itte d un le AG. agen lksw Vo by AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s r te o iva r rp fo g n do c um en 38 Rep. Jetta 2005 ➤ .34 . Be very careful: do not pinch wiring! – Carefully set mechatronic unit on dowel pins -arrow-. es.and gearbox should be at same temperature. – Do not pinch wiring. r fo ng – Ensure proper seating of seal. 1. being careful not to pinch any wiring. un le ss by ed ris o th au ua ran tee or ac ility ab y li an pt ce urposes.if you reinstall the »old« mechatronic unit. in part or in wh ole. – Tighten bolts in given order to 5 Nm + 90° (1/4 turn). Golf Variant 2010 ➤ . – Hook line -A. -Detail– Look to see if mechatronic unit has made contact correctly. ht rig py Co t. Prote cted by c o py rig ht . o V g – Push on connector and engage.2010 – Hold mechatronic unit upwards for this purpose. agen lksw Vo by AG. Electrical and electronic components for the dual clutch gearbox and their locations 39 .Golf Variant 2007 ➤ .Edition 07. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E .through -10. cial p is n mer m ot p o c erm or e t a itte v i r d p rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en – Renew both -O-rings.first in upper retaining lug. – Attach wire retainer to cover and tighten nuts to 10 Nm. (Of course a »new« mechatronic unit already has »new« seals. C op yi – Insert new bolts -arrows.) – Clean cover seal and sealing surfaces on gearbox.and tighten diagonally in several stages to 10 Nm. – Set cover over mechatronic unit.hand-tight. Volkswagen AG d agen oes ksw not l -arrows-. Jetta 2005 ➤ . – Screw in new bolts -1. – Moisten O-rings with dual clutch gearbox oil. and then in lower AG. Sender arm is not allowed to strike sender wheel. 21 . install connecting hose between charge air cooler and charge air pipe ⇒ Rep. – Install noise insulation ⇒ General body repairs. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . Removing and installing parts of charge air cooling . housing ht rig py Co t. – Reinstall any parts which may have been removed from the vehicle. exterior.2 Removing and installing mechatronic unit for dual clutch gearbox -J743(gearbox removed) Special tools and workshop equipment required do c um en 40 Rep. 27 . – Do not start engine! – Please renew filter if oil is contaminated. gr. – Change oil and filter for dual clutch gearbox ⇒ page 90 . gr. – Connect battery earth ⇒ Electrical system. Dis‐ connecting and reconnecting battery .Edition 07. agen lksw Vo by AG. Golf Variant 2010 ➤ .and engage lock by turning. Noise insulation. – If removed.noise insula‐ tion . C op yi . AG.Controls. in part or in w l purpos hole ercia . gr. Rep. Assembly overview . gr. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut dual clutch ra a unit for c s s ility ab y li an pt ce rrectness of i t to the co nform spec at i h re o n wit in t his 1.2010 – Push on connector for mechatronic unit for dual clutch gearbox -J743. Jetta 2005 ➤ . Prote cted by c o p yri gh t.Golf Variant 2007 ➤ .34 . es. Rep. is n m ot p om c r erm o e t a itte riv du p or nl f e g n – Conduct basic adjustment of mechatronic gearbox -J743. 50 .. G 1782. Its length determines the oil level in the gearbox. – Drain oil. 1.and/or oil pump can lead to gearbox failure. Vo n AG d 2010 ➤ . In particular. torque setting 3 Nm) is located in this hole. Jetta 2005 ➤ .A. Electrical and electronic components for the dual clutch gearbox and their locations ht rig py Co t. Prote cted by c o p yri gh t. – Remove this oil pipe. – Position used oil collection and extraction unit -V.2010 by ara nte e or ac ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit ♦ Used oil collection and extraction unit -V.A.Edition 07. 1.1 Removing mechatronic unit (gearbox re‐ moved) Perform the following steps: – Remove bolt -A.near pendulum support.G 1782- thi sd o cu m en Always make sure that no dirt can enter an »open« gearbox. Jetta 2011 ➤ Golf Variant ➤ . is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng ed ris o h t -V. Please also refer to the notes on the oil filter change regarding »dirty oil« ⇒ page 4 . dirt entering an »exposed« mechatronic unit for dual clutch gearbox -J743. C op yi 41 .♦ Torque wrench es.A.or a drip tray under gearbox. – Screw in overflow pipe with 3 Nm torque. agen lksw Vo by AG.lk Golf Variant gen AG a2007 oes ksw not l o V 6-speed dual clutch gu gearbox 02E . in part or in w l purpos hole ercia .2. gearboxes were constructed with 2 plugs. To gearbox manufacture date „20 September 2004“. A plastic overflow tube (with 8 mm hexagon socket head bolt. Please also refer to the notes on the oil filter change ⇒ page 4 regarding »dirty oil«.G au1331ss swage . – Following repair work.2010 6-speed dual clutch gearbox 02E . ht rig py Co t. 42 Rep. seal of »large« cover must be renewed. »Small« cover of oil pump and bolts of »large« cover must always be renewed. it is not necessary to change filter again when filling oil. in part or in w l purpos hole ercia . C op yi . Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h t Jetta 2005 ➤ . Prote cted by c o p yri gh t. doubts arise as to whether the filter must be renewed or not. is n m ot com Often.Edition ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s r te o iva r rp fo g n do c um en – Remove both -covers-. agen lksw Vo by – Insert new filter with shoulder downwards and tighten cover to 20 Nm. Jetta 2011 ➤ u. The notes on the oil filter change ⇒ page 4 can help you in reach‐ ing this decision. ra Golf Variant 2007 ➤ . Golf Variant 2010 ➤ a c s s 07. gr.– Remove the filter if necessary. housing AG.Controls. Likewise. pe rm itte d un le AG.34 . es. 2010 gen AG doe s swa an earthed object not gu ara nte eo ra c ility ab y li an pt ce rrectness of i t to the co nform spec at i h re o n wit in t his – Carefully release connector of gearbox input speed sender G182.and lay to side. If this happens. Jetta 2011 ➤ . only press against locking mecha‐ nism. es. is n m ot p om c r erm o e t a itte riv du p or nl f e g n k Vol by d e mechatronic ris unit. Jetta 2005 ➤ .Edition 07. Do not kink line. Volkswagen AG 6-speed dual clutch gearbox 02E .Before touching ⇒ page 6 . renew the sender. – Then remove it from upper clip -arrow II. 1. Prote cted by do c um en Do not screwdrivers as a lever. loosen connector. – With a second screwdriver -2-. Golf Variant 2010 ➤ . agen lksw Vo by c o p yri gh t . Take the utmost care. Do not pull on line! – Pull off connector. Electrical and electronic components for the dual clutch gearbox and their locations ht rig py Co t. The fastener of the connector can break. AG. in part or in w l purpos hole ercia . – First pull line out of lower clip -arrow I-. C op yi 43 .with oil temperature sender in multi-plate clutch -G509using a small screwdriver -1-. touch tho u a ss Golf Variant 2007 ➤ . – Using a screwdriver -1-. do not lever. Golf Variant 2007 ➤ . Golf Variant 2010 ➤ . housing AG. All 10 -securing bolts. es.diagonally. gr. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E .34 . Caution Never lift mechatronic unit on »sender arm« or lay it on arm.must be renewed.Edition 07. Jetta 2005 ➤ . C op yi . 44 Rep. ht rig py Co t.2010 – Remove securing bolts -1 … 10. When handling mechatronic unit. agen lksw Vo by Prote cted by c o py rig ht .. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng AG. Start with bolt -1-. pay special attention to the »long« sender arm.Controls. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit thi sd o cu m en – Remove mechatronic unit for dual clutch gearbox -J743. in part or in w l purpos hole ercia . C op yi 45 .Golf Variant 2007 ➤ . is n m ot p om c r erm o e t a itte riv du p or nl f e g n n AG. Prote cted by c o p yri gh t . agen lksw Vo by AG. mechatronic unit must be renewed. do c um en 1. Golf Variant 2010 ➤ . es.2010 If »arm« is damaged. in part or in w l purpos hole ercia . Jetta 2011 ➤ 6-speed dual clutch gearbox 02E .Edition 07. Electrical and electronic components for the dual clutch gearbox and their locations ht rig py Co t. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss ility ab y li an pt ce rrectness of i t to the co nform spec at i h re o n wit in t his Lay mechatronic unit to side properly. Jetta 2005 ➤ . Golf Variant 2007 ➤ .2 Installing mechatronic unit (gearbox re‐ moved) Caution Perform the following steps: Never lift mechatronic unit on »sender arm« or lay it on arm. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . If »arm« is damaged.2. is n m ot com pe rm itte d un le AG. es. r te o iva r rp fo g n do c um en 46 Rep. housing ht rig py Co t. C op yi .Edition 07. mechatronic unit must be renewed.is installed. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s – Before installation. Jetta 2005 ➤ .2010 1.34 .with oil temperature sender in multi-plate clutch -G509. make certain that gearbox input speed sender -G182. Golf Variant 2010 ➤ .Controls. agen lksw Vo by AG. Prote cted by c o py rig ht . in part or in w l purpos hole ercia . gr. Electrical and electronic components for the dual clutch gearbox and their locations ht rig py Co t.) – Moisten O-rings with dual clutch gearbox oil. by a ed ris ho t au ss G.at connection for mechatronic unit if you refit an »old« mechatronic unit. (Of course a »new« mechatronic unit already has »new« seals.Edition 07. Ensure oes not lksw o V gu that »sender arm« locates in its -fitting position-. 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 rrectness of i t to the co nf o r m spec atio h re n in wit thi sd o cu m en 1.Golf Variant 2007 ➤ . Prote cted by c o p yri gh t . Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . C op yi 47 .2010 – Renew both -O-rings. Jetta 2005 ➤ . agen lksw Vo by AG. Volkswage ran tee or ac ility ab y li an pt ce es. n AG d A agen unit on dowel – Carefully set mechatronic pin -arrow-. Golf Variant 2010 ➤ . Be very careful: do not pinch wiring! All securing bolts -1 … 10. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng AG.»by hand«. ht rig py Co t. Prote cted by – Then tighten all securing bolts -1 … 10. c o p yri gh t. . C op yi – First start all securing bolts -1 … 10. in part or in w l purpos hole ercia . housing agen lksw Vo by AG. Golf Variant 2010 ➤ . Jetta 2005 ➤ . Start with bolt -1-. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit thi sd o cu m en 48 Rep.2010 – Sender arm is not allowed to strike sender wheel.34 . es.diagonally to 5 Nm and then turn 90° further in the same sequence. -Detail– Do not pinch wiring.Golf Variant 2007 ➤ .Controls.must be renewed.Edition 07. gr. with oil temperature sender in multi-plate clutch -G509. -seal. Then into lower clip -arrow I-. Golf Variant 2010 ➤ .must be renewed. Removing – Remove mechatronic unit for dual clutch gearbox -J743⇒ page 31 . Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . if the cable is pulled on.2010 – First press wiring for gearbox input speed sender -G182. cial p is n mer m ot p o c erm or e t a itte v i r d p un le AG.3 Removing and installing gearbox input speed sender -G182.of »large« -cover. in part or in wh ole. the sender must be renewed. C op yi 49 .. They are »bathed in oil« in gearbox near the multi-clutch. Prote cted by c o p yri gh t. »Small« cover of oil pump and bolts of »large« cover must always be renewed. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en 1. – Tighten cover bolts »diagonally« to 10 Nm. Electrical and electronic components for the dual clutch gearbox and their locations ht rig py Co t. The sender will be damaged. urposes.Edition 07. – Conduct basic adjustment of mechatronic unit for dual clutch gearbox -J743. AG. Consequently. the mechatronic unit for dual clutch gearbox -J743.Golf Variant 2007 ➤ . It often occurs that the wiring for the sender is pulled. Likewise.and oil tempera‐ ture sender in multi-plate clutch -G509- Perform the following steps: Both senders are combined in one component and can be re‐ newed together only. – Press connection onto mechatronic unit.into upper clip -arrow II-. Before removal.must be removed. Jetta 2005 ➤ . After installing gearbox – Fill with oil without renewing filter ⇒ page 90 . agen lksw Vo by r fo ng Do not pull on line! 1. – Moisten sender with dual clutch gearbox oil oil and insert. – Tighten bolt to 10 Nm. gr.2010 – Remove bolt and carefully lever out sender with a screwdriver and/or pliers. Installing Reinstall »old« sender only if you know for certain: • • The sender has no defect.Edition 07. install a »new« sender.Controls. – Install mechatronic unit for dual clutch gearbox -J743⇒ page 31 . Volkswagen AG d agen oes ksw not l o V installation! unit wiring during gu y b ara d nte ise r o eo h t u ra a c s s un le ility ab y li an pt ce urposes. housing ht rig py Co t. cial p is n mer m ot p o c erm or e t a itte v i r d p rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en r fo ng 50 Rep.Golf Variant 2007 ➤ . Take special care: Never pinch mechatronic AG. Prote cted by c o p yri gh t. Jetta 2005 ➤ . The cable was not pulled on when it was removed. C op yi .34 . Golf Variant 2010 ➤ . in part or in wh ole. agen lksw Vo by AG. If this is not the case. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . 27 . is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng AG. thi sd o cu m en – Lay lint-free cloths on gearbox oil cooler and gearbox to catch escaping coolant. Jetta 2005 ➤ . agen lksw Vo by Prote cted by – Clamp off coolant hoses using hose clamps -3094.A.and re‐ move from gearbox oil cooler. in part or in w l purpos hole ercia . 2. Removing and installing gearbox oil cooler AG. c o p yri gh t.1 Removing gearbox oil cooler Perform the following steps: – Move selector lever to position „P“ position. – Remove battery and battery tray ⇒ Electrical system.Golf Variant 2007 ➤ . ht rig py Co t. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E .Edition 07. Battery.2010 2 Removing and installing gearbox oil cooler Special tools and workshop equipment required ♦ Hose clamps -3094- ♦ Torque wrench -V. gr. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit 2. C op yi 51 . Golf Variant 2010 ➤ . Rep.G 1331- es. Removing and installing battery . agen lksw Vo by Prote cted by c o py rig ht . Caution AG. ht rig py Co t.Controls. observing O-rings -C-.34 .in place. gr. . Jetta 2011 ➤ 6-speed dual clutch gearbox 02E .Golf Variant 2007 ➤ .and tighten to 20 Nm + 90° (1/4 turn). 52 Rep.. Golf Variant 2010 ➤ . is n m ot p om c r erm o e t a itte riv du p or nl f e g n rrectness of i t to the co nform spec at i h re o n wit in t his 2. housing AG. – Set gearbox oil cooler -B. do c um en – Screw in new bolts -A. in part or in w l purpos hole ercia .2 Installing gearbox oil cooler Perform the following steps: – Renew O-rings -C. Jetta 2005 ➤ .of gearbox oil cooler -B-.Edition 07. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte s i r intoho gearbox! eo ut ra a c s s No coolant must be allowed to drip ility ab y li an pt ce es.and remove gearbox oil cooler -B-.2010 – Remove bolts -A. C op yi – Attach coolant hoses to gearbox oil cooler and remove hose clamps -3094. Removing and installing gearbox oil cooler ht rig py Co t. Rep. Golf Variant 2010 ➤ . C op yi 53 . – Check coolant level and top up with coolant as needed ⇒ Rep. is n m ot com pe rm itte d un le AG. it is not necessary to change filter again when filling oil. Prote cted by c o p yri gh t. Removing and installing battery . fill with oil without renewing filter ⇒ page 90 . 27 . gr. – Following repairs. gr. Caution Do not start engine while checking coolant level if gearbox oil has not yet been filled. agen lksw Vo by AG.Golf Variant 2007 ➤ . es. – Following repair work.Edition 07. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s r te o iva r rp fo g n do c um en 2. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . 19 .2010 – Insert new filter with shoulder downwards and tighten cover to 20 Nm. in part or in w l purpos hole ercia . Removing and installing parts of cooling system . – Install battery tray and battery⇒ Electrical system. Jetta 2005 ➤ . 1 Removing oil pump Brief description The oil pump can be renewed without the gearbox being re‐ moved. gr. housing ht rig py Co t. Special tools and workshop equipment required ♦ Torque wrench -V. exterior. AG.A. Jetta 2005 ➤ .G 1331- ♦ Used oil collection and extraction unit -V. gr. 66 .A.Controls. a wish has been expressed for removal and instal‐ lation instructions.front wheel housing liner .noise in‐ sulation .2010 3 Removing and installing oil pump Important information From our experience at Volkswagen too date: you would not have received the instructions for removal of the pump. Rep. in part or in w l purpos hole ercia . – Remove noise insulation ⇒ General body repairs. agen lksw Vo by Prote cted by c o py rig ht .Edition 07. 50 . .G 1782- es. Noise insulation. The vehicle must be raised and any covers present beneath the front part of the vehicle must be removed. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng AG. The con‐ nection between suspension link and suspension strut does not need to be separated. 54 Rep. Rep. As‐ sembly overview . exterior. Wheel housing liner. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . The drive shaft does not need to be re‐ moved.Golf Variant 2007 ➤ . You do not need to perform any „basic adjustment“. Assembly overview . Only the dual clutch gearbox oil and oil pump cover must be renewed. C op yi thi sd o cu m en – Remove lower part of front left wheel housing liner ⇒ General body repairs. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit 3. gr. Nevertheless.34 . Golf Variant 2010 ➤ . G 1782under gearbox. – Remove bolt -A. 3 Nm torque. Removing and installing oil pump 55 . Please also refer to the notes on the oil filter change regarding »dirty oil« ⇒ page 4 .G 1782.Golf Variant 2007 ➤ . gearboxes were constructed with 2 plugs. ht rig py Co t.2010 – Position used oil collection and extraction unit -V.A. A plastic overflow tube (with 8 mm hexagon socket head bolt. torque setting 3 Nm) is located in this hole. es. There will still be oil in oil pump cover.A. AG.near pendulum support. – Remove this oil pipe.and remove oil cooler cover -A-.off dowel pins and pull out oil pump drive shaft. Golf Variant 2010 ➤ . lkswa Vo – Screw in overflow pipe with. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng – Used oil collection and extraction unit -V. agen lksw Vo by Prote cted by c o p yri gh t .for a ss – plug.Edition 07. – Drain oil. To gearbox manufacture date „20 September 2004“. C op yi 3.remains under gearbox.and pull oil pump -1. does not gu ara nte eo ra c ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit – Remove bolts -arrows. thi sd o cu m en – Remove bolts -arrows. Its length determines the oil level in the gearbox. in part or in w l purpos hole ercia . gen AG gen AG wa olks yV b ed ris Renew useal tho -arrow. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . Jetta 2005 ➤ . Golf Variant 2010 ➤ .for oil pump into gearbox as far as stop. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng AG. – Always use a new metal seal -B-. Prote cted by c o p yri gh t. observe splines of input shaft and prop‐ er seating of dowel pins. uppermost bolt -arrow. housing agen lksw Vo by AG. in part or in w l purpos hole ercia . thi sd o cu m en 3 bolts with flat heads.to remove upper bolt. gr. • The 2 dowel pins -C.2 – Push input shaft -A. 3.34 . Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s ility ab y li an pt ce Installing oil pump rrectness of i t to the co nf o r m spec atio h re n in wit Various bolts for oil pump -1All 4 bolts with flat heads -arrows♦ 5 Nm + 90° (1/4 turn) ht rig py Co t.) ♦ Flathead bolts: 8 Nm + 90° (1/4 turn) 56 Rep.Edition 07.with countersunk head Torque setting ♦ Countersunk head bolt: 8 Nm without additional turn (tighten with socket -T10054.must be located in gearbox housing.Golf Variant 2007 ➤ . Jetta 2005 ➤ . Turn input shaft slightly whilst doing this.Controls.2010 It may be necessary to use socket -T10054. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . es. – When fitting oil pump. C op yi Torque setting . There is no oil in the gearbox. – Install noise insulation te ris o h gr. Rep. – Change oil and filter for dual clutch gearbox ⇒ page 90 .noise insula‐ e or a ut c tion . Rep. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . »New« oil must now be filled and adjusted to the proper level.Golf Variant 2007 ➤ .diagonally in several stages to 8 Nm. – Install left wheel housing liner ⇒ General body repairs. Noise ainsulation. does agen front wheel housing linero. Prote cted by c o p yri gh t. cial p is n mer m ot p o c erm or e t a itte v i r d p un le rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en r fo ng ht rig py Co t. ss V by t gu a ility ab y li an pt ce urposes.in place and tighten new bolts -arrows. 50 . C op yi 3. exte‐ rior. in part or in wh ole. Wheel housing wagen AG overview G. Assembly overview . gr. Golf Variant 2010 ➤ . agen lksw Vo by AG. Jetta 2005 ➤ .2010 – Set new oil pump cover -A. 66 .Edition 07. no lksw ran ed ⇒ General body repairs. exterior. Removing and installing oil pump 57 . VolksAssembly Aliners. Jetta 2005 ➤ .2010 4 Renew seal on selector shaft lever Special tools and workshop equipment required ♦ Tube -VW 423- ♦ Puller hooks -T20143- ♦ Torque wrench -V.Edition 07. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng n AG. Prote cted by c o p yri gh t . Golf Variant 2010 ➤ . – Unbolt lever -A. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . housing ht rig py Co t.Controls.A. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit – Remove selector lever cable from gearbox ⇒ page 61 . C op yi .Golf Variant 2007 ➤ . thi sd o cu m en 58 Rep. gr.and carefully pry off selector shaft. in part or in w l purpos hole ercia .34 . agen lksw Vo by AG.G 1331- es. • Closed side of oil seal -arrow. ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s r te o iva r rp fo g n do c um en – Apply lever and tighten nut to 20 Nm. Do not cant oil seal in the process. Renew seal on selector shaft lever 59 .. – Install and adjust selector lever cable on gearbox ⇒ page 61 . C op yi 4. es.Edition 07. – pe rm itte d – Lightly oil outer circumference of oil seal.Golf Variant 2007 ➤ . AG. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . agen lksw Vo by Prote cted by c o py rig ht .2010 – Pry seal out -in direction of arrow-. is n m ot com un le AG. Golf Variant 2010 ➤ . in part or in w l purpos hole ercia .points towards tube -VW 423. Jetta 2005 ➤ . Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o e o sealing Fill space between sealing lip and dust lip -arrow. Selector shaft lever fits on splines in only one position. s s – Drive in new seal to stop. ht rig py Co t.with h ut ra a c grease -G 052 128 A1. in part or in w l purpos hole ercia . agen lksw Vo by Prote cted by c o p yri gh t .2009 1 . Jetta 2011 ➤ 6-speed dual clutch gearbox 02E .Golf Variant 2007 ➤ . Golf Variant 2010 ➤ . 5. pull lock button out past its pressure point. 2 . If necessary.Selector lever and selector mechanism ❑ With selector lever lock n AG.Bolt with spring ❑ 3 Nm 60 Rep. Jetta 2005 ➤ .Pin ❑ Removing ⇒ page 61 ❑ Do not grease . Volkswagen AG do es n wage s k solenoid -N110l ot g o yV ua b ran ed ❑ Emergency release s i tee r o h ⇒ page 72 t or u ac a s s ❑ Brief instructions for re‐ moving and installing: – – Remove centre con‐ sole. For emergency release. C op yi 4 .selector mechanism in vehicles up to 02. es. gr. Se‐ cure lock button with a cable tie or appropriate wire against being pressed in.Locking plate ❑ Always renew after removing ht rig py Co t.34 . This will pre‐ vent lock button from being accidentally pressed into the knob. disconnect or remove parts of ex‐ haust system ⇒ Rep. gr. Remove heat shield beneath selector mechanism.Edition 07. Adjust selector lever cable after installing ⇒ page 70 .2010 5 Selector mechanism WARNING Before working on vehicle with engine running. Remove Bowden cable from gearbox ⇒ page 61 . is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit – – – thi sd o cu m en 3 . move selector lever into position „P“ and apply handbrake. housing AG.1 Overview . 5 .Controls. ❑ Before removing knob.Selector cover with knob ❑ Do not remove knob without reason. on‐ ly the cover needs to be unclipped ⇒ page 72 . Removing and installing parts of ex‐ haust system . 26 . Selector housing ❑ With seal 8 . 4 un le rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en 5.vehicles up to 02.Nut ❑ 9 Nm ❑ Qty.2 Removing and installing selector lever cable . Golf Variant 2010 ➤ .Selector lever cable ❑ Bowden cable must not be greased ❑ Removing and installing ⇒ page 61 ❑ Checking ⇒ page 70 ❑ Adjusting ⇒ page 70 12 . cial p is n mer m ot p o c erm or e t a itte v i r d p 11 .Adjuster screw ❑ 13 Nm 9 . agen lksw Vo by Removing ht rig py Co t. Bowden cable must be checked for ease of movement and be adjusted. in part or in wh ole.2009 Note AG. – Move selector lever to position „S“ position.Securing clip ❑ Always renew after AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a removing c s s ility ab y li an pt ce urposes. Jetta 2005 ➤ . Following installation. Prote cted by c o p yri gh t.Edition 07. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E .Golf Variant 2007 ➤ .Securing clip ❑ Always renew after removing 10 .2010 6 . 4 7 . C op yi r fo ng 5. Selector mechanism 61 .Hexagon flange nut ❑ 8 Nm ❑ Qty. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . cial p is n mer m ot p o c erm or e t a itte v i r d p un le AG.on the cable support bracket.Edition 07. gr. Re‐ moving and installing parts of exhaust system . – Raise vehicle. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en – Remove locking plate of cable support bracket. heat shield under selector mechanism and. Jetta 2005 ➤ . C op yi . – To remove Bowden cable and/or selector mechanism.34 . Prote cted by c o py rig ht . 26 . the rubber grommet on the cable could be damaged.beneath selector lever. agen lksw Vo by AG. Securing clips must be renewed when Bowden cable is later adjusted. housing ht rig py Co t. urposes.Golf Variant 2007 ➤ . – Remove -selector housing. Golf Variant 2010 ➤ . gr. in part or in wh ole. parts of exhaust system must now be removed ⇒ Rep.2010 Loosen adjustment screw -arrow-. Note Use pliers to remove the securing clip -B. Always renew locking plate.Controls. r fo ng 62 Rep. Do not use a sharp-edged lever. if necessary. – Remove securing clips -A.and -B-. Otherwise. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce rrectness of i t to the co nform spec at i h re o n wit in t his -Selector housing. agen lksw Vo by AG. in part or in w l purpos hole ercia .Edition 07. C op yi 5.is pushed forwards slightly on cable. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . Prote cted by c o p yri gh t. Jetta 2005 ➤ . Golf Variant 2010 ➤ . Selector mechanism 63 . do c um en ht rig py Co t.2010 es.Golf Variant 2007 ➤ . is n m ot p om c r erm o e t a itte riv du p or nl f e g n AG. Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed dual clutch gearbox 02E - Edition 07.2010 To remove cable, securing tab must be pushed forwards -1-. – At same time, push -pin- up with a screwdriver -2-. – Please insert -screwdriver- from underneath whilst pushing securing tab forwards. es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss ility ab y li an pt ce rrectness of i t to the co nform spec at i h re o n wit in t his do c um en 64 Rep. gr.34 - Controls, housing ht rig py Co t. agen lksw Vo by AG. Prote cted by c o p yri gh t . C op yi Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed dual clutch gearbox 02E - Edition 07.2010 Clarification: ♦ -1- Push tab forwards ♦ -2- Push pin up – Remove selector lever cable. Remove selector housing from cable. Installing Do not grease cable. – Route selector lever cable without tension. Also insert in cable support bracket on gearbox. Do not secure with securing clips yet. Do not clip in ball head. 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 AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit thi sd o cu m en ht rig py Co t. agen lksw Vo by AG. Prote cted by c o py rig ht . C op yi 5. Selector mechanism 65 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed dual clutch gearbox 02E - Edition 07.2010 – Ensure that selector lever cable is properly routed during in‐ stallation. If the sheet metal is bent downwards, it may cause noises. The cable will »vibrate« against the sheet metal. – Observe sheet metal. Press it back up in the tunnel during installation -direction of arrow-. – Put selector housing onto cable. – 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 70 , insert locking plate. AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce 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 rrectness of i t to the co nf o r m spec atio h re n in wit – Attach cable with new locking plate on cable support bracket of selector mechanism. thi sd o cu m en 66 Rep. gr.34 - Controls, housing ht rig py Co t. agen lksw Vo by AG. Prote cted by c o py rig ht . C op yi 2010 es. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s r te o iva r rp fo g n do c um en – Remove selector housing. AG. agen lksw Vo by Prote cted by c o py rig ht . heat shield and exhaust system ⇒ Rep. gr. Golf Variant 2010 ➤ . C op yi 5. Removing and installing parts of exhaust system . ht rig py Co t.Golf Variant 2007 ➤ .Edition 07. Jetta 2005 ➤ . Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . is n m ot com pe rm itte d un le AG. – Check cable ⇒ page 70 . Selector mechanism 67 . in part or in w l purpos hole ercia . 26 . Se‐ cure locking button with a cable tie or appropri‐ ate wire against being pressed in. Prote cted by c o py rig ht .Securing clip ❑ Always renew after removing 8 . on‐ ly the cover needs to be unclipped ⇒ page 72 .Edition s07. housing ht rig py Co t.2009 onwards ri ho ut a ss tee or ac ility ab y li an pt ce 1 . Jetta 2005 not olks gu yV b ara 6-speed dual clutch gearbox 02E . gr.Controls. For emergency release.3 Overview of selector mechanism .does wag ➤ .vehicles from 03.Adjuster screw ❑ 13 Nm rrectness of i t to the co nf o r m spec atio h re n in wit thi sd o cu m en 7 .2010 ed n es. Jetta 2011 ➤ Golf Variant 2007 ➤ .Selector cover with knob ❑ Do not remove knob without reason. in part or in w l purpos hole ercia . Golf Variant 2010 ➤ . ❑ Before removal of knob.Selector mechanism with selector lever and selector lev‐ er cable ❑ With selector lever lock solenoid -N110❑ Cable must not be greased ❑ Removing and installing ⇒ page 69 ❑ Checking ⇒ page 70 ❑ Adjusting ⇒ page 70 3 . ❑ Removing and installing selector lever knob ⇒ page 73 2 . This will pre‐ vent lock button from being accidentally pressed into the knob.Securing clip ❑ Always renew after removing 68 Rep.34 . is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng olkswagen AG en AG. pull lock button out past its pressure point. C op yi .Selector housing 6 .Bolt ❑ 8 Nm 4 . V 5. 4 5 . agen lksw Vo by AG.Hexagon flange nut ❑ 8 Nm ❑ Qty. Both are removed together. Removing and installing parts of exhaust system . In the engine compartment. Torque setting: 8 Nm – Raise vehicle. remove parts of exhaust system if necessary ⇒ Rep. Bowden cable must be checked for ease of movement and be adjusted. – Remove selector lever handle ⇒ page 73 . C op yi – Remove 4 bolts. AG. To do so. Often. This makes subsequent removal of selector mechanism easier. it may be necessary to provide instal‐ lation space. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . 5. it is necessary to remove air filter. agen lksw Vo by Prote cted by c o py rig ht . 68 . Jetta 2005 ➤ . Note Use pliers to remove the securing clip -B. Volkswagen A G do es n ot g ua ran tee or ac Removing and installing selector mech‐ anism with selector lever and selector lever cable .2009 on‐ wards Selector mechanism and selector lever cable are not allowed to be separated from one another. the rubber grommet on the cable could be damaged. Note Following installation. ht rig py Co t.Edition 07. gr. Loosen adjustment screw -arrow-. is n m ot com Perform the following steps: un le ss n wage olks V by ed ris o th au Golf Variant 2007 ➤ . r te o iva r rp fo g n ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s – Move selector lever to position „P“ position.5. it may be necessary to remove centre console. Otherwise.4 pe rm itte d es. 26 . in part or in w l purpos hole ercia . Golf Variant 2010 ➤ . Do not use a sharp-edged lever. In the interior. do c um en – Remove centre console ⇒ Rep.vehicles from 03. gr. – Remove heat shield beneath selector mechanism. Selector mechanism 69 .on the cable support bracket.2010 AG. in part or in wh ole. un le agen AG n AG.6 Adjusting selector lever cable ht rig py Co t.Golf Variant 2007 ➤ .34 . c o p yri gh t . – Before you put on ball head: check cable ⇒ page 70 . gr. ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en 5. 5.2010 – Remove securing clips -A. Put removed end down so it r ac a ss Brief description Checking selector lever cable olksw does not rub against anything. Do not grease connections of cable! Checking – Move selector lever to position »P« position.Controls. V does wage not olks V gu y b ara d e nte rismust be removed from gearbox so that its Selector lever cable o eo h t u ease of movement can be checked. Removing and installing parts of exhaust system . gr. 26 . Jetta 2005 ➤ . r fo ng urposes. 66 . – Move selector lever repeatedly from »P« to »S« and back to »P«. – Install all parts of exhaust system which were removed ⇒ Rep. – Adjust cable ⇒ page 70 . gr. Special tools and workshop equipment required agen lksw Vo by Prote cted by 70 Rep. – Remove cable from lever on gearbox.5 Then the selector lever cable must be adjusted ⇒ page 70 .Edition 07. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . housing AG. – Remove selector mechanism. – Install cable using new securing clip and »loosened« adjusting screw.and -B-. cial p is n mer m ot p o c erm or e t a itte v i r d p Then the selector lever must be moved and after that. Install in reverse order of removal. – Install heat shield ⇒ Rep. C op yi . Golf Variant 2010 ➤ . the Bowden cable must be reattached to the gearbox. – Adjust selector lever cable after installing ⇒ page 70 . • Selector lever must move easily. Securing clips must be renewed when Bowden cable is adjusted. Selector mechanism agen lksw Vo by AG. ♦ The cable itself or the selector mechanism has been removed and installed.and -B-. C op yi 71 . for example to install it free of tension. ♦ The engine and/or gearbox has been removed and installed. ♦ The position of the engine and gearbox is shifted. n AG. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . – Push lever »backwards«. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h back«. r fo ng ht rig py Co t.Edition 07. ♦ Parts of the assembly mounting have been removed and in‐ stalled. t or u ac a ss ility ab y li an pt ce urposes. Golf Variant 2010 ➤ . 5.2010 ♦ Torque wrench -V. Adjusting – Move selector lever in vehicle to „P“ position. Prote cted by c o p yri gh t . Jetta 2005 ➤ .and new securing clips -A.A. „P“ is in second detent. Shift lever on gearbox to position „P“. Lever on gearbox must be pressed »all the way If you are not certain: – Pull lever forwards. in part or in wh ole.G 1331- The selector lever cable must always be adjusted whenever ♦ The selector lever cable has been removed from the gearbox. cial p is n mer m ot p o c erm or e t a itte v i r d p un le rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en – Install cable with loosened adjusting screw -arrow.Golf Variant 2007 ➤ . Volkswagen AG d agen oes ksw not l o V gu set handbrake.Golf Variant 2007 ➤ .34 .Controls.from right to left.2010 – Push lever on gearbox backwards -arrow-. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E .7 Emergency release of selector lever AG.2009 – Or press on the pin of the solenoid. is n m ot p om c r erm o e t a itte riv du p or nl f e g n – Press yellow plastic part -arrow. This also puts gearbox in position „P“. gr. Golf Variant 2010 ➤ . Jetta 2005 ➤ . to be sure that the gearbox is in „P“ (parking lock engaged).to 13 Nm. C op yi . housing ht rig py Co t. In this way the ⇒ core of the Bowden cable finds it optimal position.Edition 07. es. – Tighten adjusting screw -arrow. by ara d e nte is r o eo h ut ra a c s s Do not remove knob. Note Raise vehicle. – Gently push knob of selector lever forwards and backwards but under no circumstances must you shift out of „P“. Prote cted by c o p yri gh t. in part or in w l purpos hole ercia . It should not be possible to turn both front wheels to‐ gether in the same direction. This completes the adjustment. ility ab y li an pt ce rrectness of i t to the co nform spec at i h re o n wit in t his do c um en 72 Rep. 5. – Unclip selector cover and hold to side. – Depress brake pedal or Vehicles up to 02. agen lksw Vo by AG. Golf Variant 2007 ➤ . in part or in wh ole.8 Removing and installing selector lever knob It is possible with all knobs that lock button is pressed into knob. – Secure locking button with a cable tie or wire against being pressed in. r fo ng – Lock the handle again after installing. Selector mechanism 73 . agen lksw Vo by Prote cted by c o p yri gh t. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en 5. ht rig py Co t. pull lock button out past its pressure point. cial p is n mer m ot p o c erm or e t a itte v i r d p un le AG.2010 Vehicles from 03. – Before removal. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . Golf Variant 2010 ➤ . AG. C op yi 5. Jetta 2005 ➤ . Do not install a knob with the locking button pressed in. urposes. – Unclip cover.2009 onwards – Press yellow plastic wedge -arrow-. press the sleeve under the handle back down. To do this. – Push sleeve upwards to release knob.Edition 07. The locking button is already in installation position.Controls. 5. On a right-hand drive vehicle. Golf Variant 2010 ➤ . gr. cial p is n mer m ot p o c erm or e t a itte v i r d p un le AG.Golf Variant 2007 ➤ . In vehicles with lock button at front on knob -arrowLock button -arrow. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . housing AG.back into groove before installing knob. – Pull off knob upwards. urposes.9 Checking selector mechanism The starter must not operate in the selector lever positions „R“.34 . unclip knob trim upwards. starter must only operate in selector lever positions „P“ and „N“ when lock button is not pressed.Edition 07. in part or in wh ole. – Lock the handle again after installing. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en r fo ng – However. agen lksw Vo by Prote cted by c o p yri gh t. 74 Rep. Jetta 2005 ➤ . – Pull connector from cover. „D“ or „S“. should this happen.2010 – You only have to remove transport guard from »new« handles.is not allowed to be pressed in when knob is being fitted and removed. Press the sleeve under the handle back down. ht rig py Co t. C op yi . – Press small lever for pull rod -arrow. Edition 07. C op yi 5. • Shift selector lever into Tiptronic gate. Jetta 2005 ➤ . lever s no swa solenoid for selector k l o t gu V lock should only engage afterdabout 1 second. in part or in w l purpos hole ercia . • Brake pedal is depressed: Solenoid for selector lever lock releases selector lever. solenoid for selector lever lock must not engage and block selector lever. Selector lever in „N“ position and ignition switched on • Brake pedal not depressed: Selector lever is locked and cannot be shifted out of „P“ position with the lock button pressed. AG.Golf Variant 2007 ➤ . Selector mechanism 75 . It is pos‐ sible to shift into a driving gear. It is pos‐ sible to shift into a driving gear. Golf Variant 2010 ➤ . „+“ and „-“ symbols must light up. ht rig py Co t. When travelling at speeds below 5 km/hn(almost stationary) and agen AG . Slowly shift selector lever from „P“ through to „S“. is n m ot p om c r erm o e t a itte riv du p or nl f e g n a Selector lever in „P“ position and ignition switched on ss h ut or ac ility ab y li an pt ce Selector lever is locked and cannot be shifted out of „P“ position with the lock button pressed. Prote cted by c o p yri gh t. When the selector lever is shifted into the Tiptronic gate. Solenoid for selector lever lock blocks selector lever. Solenoid for selector lever lock blocks selector lever. the se‐ lector lever position display in the dash panel insert must change from „P R N D S“ to „6 5 4 3 2 1“. Selector lever position display Simultaneous illumination of all selector lever position display segments indicates gearbox emergency running mode. agen lksw Vo by rrectness of i t to the co nform spec at i h re o n wit in t his do c um en Selector lever in position „Tiptronic“ The illumination of the „D“ symbol in the selector mechanism cov‐ er must go out. Selector lever can‐ by ara nte ise not be shifted out of „N“ position until brake pedal is depressed. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . Selector lever can be shifted into a driving range. Ignition and light switched on The respective symbol in the shift mechanism cover lights up. • Brake pedal is depressed: Solenoid for selector lever lock releases selector lever. r o e • Brake pedal not depressed: es. checking whether selector lever position in dash panel insert corresponds to selector lever position.2010 When selector lever is shifted to position „N“ at speeds above 5 km/h. Volksw ge AG doe shifting into selector lever position „N“. 34 .is not fixed with the pins. If the job is done correctly.1 Removing gearbox Brief description The gearbox is removed downwards separately. The engine and gearbox must be supported before the left subframe mounting is unbolted.Edition 07. Torque settings ⇒ page 87 rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en 6. air filter and starter are removed »from above«. It is recommended to read this information »before« removing gearbox. Coolant hoses are disconnected »from above«. locating pins -T10096. which may lead to customer complaints.Golf Variant 2007 ➤ . Jetta 2005 ➤ . gr.are necessary. Prote cted by c o py rig ht . Volkswagen AG d 6-speed dual clutch gearbox 02E .and -both suspension links-. the wheels must later be aligned. In any case. 76 Rep.. Their benefit is enormous. agen lksw Vo by AG. Jetta 2011 ➤ AG. refer to ⇒ Rep.can be properly fixed and the subframe removed. the subframe can be removed and reinstalled without subsequently causing increased tyre wear. The battery.Controls. Installing gearbox ⇒ page 86 .together with -pendulum support-. Golf Variant 2010 ➤ . cial p is n mer m ot p o c erm or e t a itte v i r d p un le s ol yV db e ris tho au ot g ua ran tee or ac ility ab y li an pt ce Remove gearbox ⇒ page 76 . 40 . gr. »From below«: Remove -subframe. -steering box. housing ht rig py Co t. Then the position of the -subframe. C op yi . r fo ng For information on how to remove the -subframe-.2010 agen oes ksw n 6 Removing and installing gearbox s urposes. wheel alignment would be an unnecessary and ex‐ pensive additional job! Save yourself this work and your customer the expense! It requires only a small effort to install the locating pins -T10096. If the position of the -subframe. in part or in wh ole. In this case. Prote cted by c o p yri gh t. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s ♦ Or 2 hose clamps to 25 mm Ø -3094r te o iva r rp fo g n do c um en 6.Edition 07. is n m ot com pe rm itte d un le AG. C op yi 77 . Jetta 2011 ➤ 6-speed dual clutch gearbox 02E .2010 Special tools and workshop equipment required ♦ Support bracket -10-222A♦ Adjustment plate -3282/42 A♦ Adapter -10-222A/8♦ Adapter -10-222A/3♦ Gearbox support -3282♦ Insert tool.Golf Variant 2007 ➤ . Golf Variant 2010 ➤ . 18 mm -T10179- ♦ 2 hose clamps to 40 mm Ø -3093es. Jetta 2005 ➤ . Removing and installing gearbox ht rig py Co t. agen lksw Vo by AG. in part or in w l purpos hole ercia . in part or in wh ole. gr. 23 .G 1383 A- r fo ng ♦ Bracket -T10346- Perform the following steps: – Move selector lever to position »P« position.Controls. gr.34 .2010 6-speed dual clutch gearbox 02E y b ♦ Pin -3282/29urposes. agen lksw Vo by AG. Prote cted by c o p yri gh t. gr. Jetta 2005 s no ksw l o t gu V . Removing and installing air filter 78 Rep. 24 . cial p is n mer m ot p o c erm or e t a itte v i r d p un le ss ed ris o h t au ara nte e or ac ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en ♦ Engine and gearbox jack -V. – Remove complete air filter housing. housing ht rig py Co t.AG. Golf Variant 2010 ➤ . Jetta 2011 ➤ doe agen ➤ . ♦ Vehicles with petrol engines ⇒ Rep.Edition 07. Volkswagen AG Golf Variant 2007 ➤ . Removing and installing air filter ♦ Vehicles with diesel engines ⇒ Rep. C op yi .A. Jetta 2011 ➤ gen AG does wa2007 not olks V gu gearbox 02E . moving and installing agen AG . – Clamp off coolant hoses using hose clamps -3093/3094. – Seal off gearbox oil cooler with clean plugs.– es. Remove cable with great care from cable support bracket on gearbox. Note ht rig py Co t. do not clip »new« securing clips on until cable has been checked and adjusted ⇒ page 70 . Jetta 2005 ➤ . Otherwise. gr. During later installation. Prote cted by Both securing clips must be renewed when Bowden cable is later adjusted. But then observe Bowden cable when lowering gearbox. Golf Variant 2010 ➤ .2010 6-speed dual clutch y b a d olksw ⇒ Rep. Cable may also be pushed slightly backwards out of cable support bracket and removed later when gearbox is lowered. Re‐ ran tee or ac ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit thi sd o cu m en – Remove selector lever cable from gearbox. AG.Edition 07.V Golf Variant ➤ . Battery. 27 . Removing and installing gearbox 79 . agen lksw Vo by c o p yri gh t . – Lay lint-free cloths on gearbox oil cooler and gearbox to catch escaping coolant. Do not use a sharp-edged lever.and remove hoses from gearbox oil cooler. Use pliers to remove the securing clip on the cable support brack‐ et. C op yi 6. the rubber grom‐ met on the cable could be damaged. Do not bend cable when doing this. 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 e ris tho u Remove battery and battery tray a ss battery . in part or in w l purpos hole ercia . housing ht rig py Co t. Check the various engines below to see which tools are required to support the engine.by turning and pull off connector. Rep. agen lksw Vo by AG. gr. Jetta 2005 ➤ . These tools are appropriate for this. – Unbolt wiring retainer from front of »black« gearbox cover (2 M6 nuts). gr.⇒ Electrical system. is n m ot com pe rm itte d un le AG. Prote cted by c o py rig ht . Golf Variant 2010 ➤ .Edition 07. – Now remove all upper connecting bolts between engine and gearbox.. es. It is advisable to remove the »lower« bolt first. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s r te o iva r rp fo g n do c um en – Remove both filler pieces from upper edge of left and right wings.Controls. – Release mechatronic unit connector -1.Golf Variant 2007 ➤ . 80 Rep. C op yi . – If there are hose and cable connections in area of engine sup‐ port eye for support bracket -10-222A. remove these now.2010 – Remove starter -A.34 . Re‐ moving and installing starter . Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . 27 . 2010 s s ility ab y li an pt ce rrectness of i t to the co nform spec at i h re o n wit in t his do c um en Adapter -10 . Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o . Golf Variant 2010 ➤ . but do not raise.222 A♦ Adapter -10 . Prote cted by c o p yri gh t.222 A /3♦ Adapter -10 .222 A /12- 2. C op yi 81 .222 A /10- 2.Golf Variant 1.9 l TDI engine – Support engine and gearbox. ♦ Support bracket -10 .0 l TDI engine . is n m ot p om c r erm o e t a itte riv du p or nl f e g n AG.222 A /8- es.0 l TDI engine . Jetta 2007 th ➤ e o 2011 ➤ u ra a c 6-speed dual clutch gearbox 02E Edition 07.Jetta 2005 ► and Golf Variant 2007 ► – Support engine and gearbox.Golf Variant 2010 ► – Support engine and gearbox. Removing and installing gearbox ht rig py Co t. but do not raise. Jetta 2005 ➤ . but do not raise.222 A /8♦ Hook -10 . in part or in w l purpos hole ercia .222 A /3♦ Adapter -10 .222 A♦ Adapter -10 . agen lksw Vo by AG. ♦ Support bracket -10 .222 A /16♦ Hook -10 . 6.222 A /2♦ Shackle -10 . but do not raise. housing ht rig py Co t. Jetta 2005 ➤ .2010 es.222 A /181. Golf Variant 2010 ➤ . C op yi .4 l TSI engine ♦ Support bracket -10 .222 A♦ Adapter -10 .Edition 07. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E .222 A♦ Hook -10 . gr.34 . 82 Rep.222 A /10♦ Adapter -10 .222 A /8- do c um en – Support engine and gearbox. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce rrectness of i t to the co nform spec at i h re o n wit in t his ♦ Support bracket -10 . agen lksw Vo by AG. is n m ot p om c r erm o e t a itte riv du p or nl f e g n AG. Prote cted by c o p yri gh t.Golf Variant 2007 ➤ .Controls. in part or in w l purpos hole ercia . »smooth side« to engine compartment ♦ Bracket -T10346♦ Use spacer tube -10 . Prote cted by c o p yri gh t. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E .222 A /8. All 4 supports of lifting platform must be at same height. – Remove noise insulation ⇒ Rep. ♦ Support bracket -10 . gr. – To do this. 66 . do not lift.222 A♦ Adapter -10 .222 A /3♦ Adapter -10 .Golf Variant 2007 ➤ . use a collar bolt M 6 or a securing bolt for battery tray. gr. agen lksw Vo by AG. gr. in part or in wh ole.Edition 07. AG. but do not raise.to rear of the 3 mounting holes for bat‐ tery tray. Repairing drive shafts . Front wheel housing liner . Tight‐ ening torque: ⇒ Rep. – Remove front wheels. Removing and installing gearbox ht rig py Co t. 40 .0 l TFSI engine – Bolt bracket -T10346.noise insulation . – Loosen wheel bolts on front left and front right. cial p is n mer m ot p o c erm or e t a itte v i r d p – Remove lower part of front left wheel housing liner ⇒ Rep. rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en r fo ng 6. – If present.222 A /17. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo Assembly overview h ut ra a c s s un le ility ab y li an pt ce urposes. – Raise vehicle. 50 . Jetta 2005 ➤ .2010 2. C op yi 83 . remove heat shield above right drive shaft. . Golf Variant 2010 ➤ .on the »front« spindle Continuation for all engines – Take up weight of engine/gearbox assembly on spindles. – Support engine and gearbox. Removing and installing wheel housing liner. 40 . 40 .2010 – Separate exhaust system at clamp and remove exhaust sys‐ tem bracket from subframe -arrows. Note AG. – Unbolt drive shafts from gearbox. cial p is n mer m ot p o c erm or e t a itte v i r d p rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en – Raise right drive shaft as high as possible and secure.Controls. Golf Variant 2010 ➤ . Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . gr.Edition 07. suspension links. gr. gr. Note The flexible joint of the front exhaust pipe must not be bent more than 10° – danger of damage.34 . agen lksw Vo by – A small cover plate may be located above the right drive shaft flange on the intermediate plate for engine and gearbox. anti-roll bar. 84 Rep. – Unbolt ⇒ pendulum support from gearbox. ility ab y li an pt ce – Remove subframe with steering box ⇒ Rep. in part or in wh ole. Removing and installing subframe with steering box .Golf Variant 2007 ➤ . – Tie up front exhaust pipe.⇒ Engine ⇒ Rep. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra necessary to perform wheel a c s s un le If -subframe. Prote cted by c o p yri gh t. Jetta 2005 ➤ . AG. 26 . housing ht rig py Co t. gr. urposes. C op yi r fo ng . – Secure subframe before removal ⇒ Running gear ⇒ Rep.is not located. Re‐ move this cover plate -A-. – Put left drive shaft to rear and secure (do not damage surface protection when doing this). Sub‐ frame. it will be alignment later. To remove gearbox 02E.Edition 07.with ad‐ justment plate -3282/42 A. Jetta 2011 ➤ wage ➤ . – Secure both other support elements on gearbox as shown in illustration. – Raise gearbox and engine support -V. Prote cted by c o p yri gh t . ♦ Illustration shows dual clutch gearbox 02E „four-wheel drive“. agen lksw Vo by AG. Transporting gearbox and securing to assembly stand ⇒ page 89 .. »observing selector lever cable« and lower gearbox. ht rig py Co t. – Remove remaining engine/gearbox connecting bolts. • The arrow on adjustment plate -3282/42 A. – Align gearbox support -3282. C op yi 6. Installing gearbox ⇒ page 86 .G 1383 A.into gearbox. – Screw pin -3282/29. in part or in w l purpos hole ercia . Golf Variantd not olk V gugearbox 02E .2010 6-speed dual clutch y b a d olksw bracket -A-. do c um en – Align arms of gearbox support according to holes in adjust‐ ment plate -3282/42 A. Support elements are identical on „front-wheel drive“.A. – Press gearbox off engine. V Golf Variant s2007 2010 oes ➤ .parallel to gearbox.222 A.. Jetta 2005 ➤ . The gearbox is separated from the engine in this position. e ris tho for u and -2a ss agen AG n AG. Removing and installing gearbox 85 . Note ♦ Rather than as shown in illustration on adjustment plate .from below to support gearbox. is n m ot p om c r erm o e t a itte riv du p or nl f e g n – Then lower engine and gearbox slightly using spindles of sup‐ port bracket -10 . set up gearbox support -3282.so that bracket can be removed. – Screw in support elements as illustrated on adjustment plate -3282/42 A. front support element is bolted onto gearbox as shown -arrow-. ran tee or ac ility ab y li an pt ce rrectness of i t to the co nform spec at i h re o n wit in t his – Remove bracket -arrow-. – Position engine and gearbox jack -V.A.G 1383 A.and put onto engine and gearbox support -V.– Remove all bolts -1- es.under vehi‐ cle..points in direction of travel.A.G 1383 A. Torque settings ⇒ page 87 . »something has gone wrong«! – Turn crankshaft slightly if necessary. AG. it must be renewed ⇒ Rep. Draining and filling coolant . Be sure to insert it in cable support bracket »early«. 86 Rep.Controls. If it is damaged Installing gearbox ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en If not. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . r fo ng urposes. housing agen lksw Vo by – Readjust gearbox support until engine and gearbox are »aligned with each other«.. Crank‐ shaft. gr. Jetta 2005 ➤ . un le AG. grease lightly with high-temperature grease -G052133A2. – Check for proper seating of intermediate plate. ht rig py Co t. Parts of cooling system. Volkswagen AG d agen oes ksw not l o gu yV b ara dimportant steps Install in reverse order of removal. – Check coolant level and top up if necessary ⇒ Rep. C op yi . gr. Bowden cable must not be greased. – Securing clips for selector lever cable must be renewed. – Check for proper seating of both dowel sleeves between en‐ gine and gearbox. – Guide selector lever cable as soon as possible into its cable support bracket. – Always adjust selector lever cable ⇒ page 70 . Golf Variant 2010 ➤ .2010 6. gr. pulling needle bearing from crankshaft and driving in .Golf Variant 2007 ➤ .in crankshaft. 13 . 19 . Check Bowden cable as soon as gearbox is raised. – End of gearbox shaft (but not splines) also must be lightly greased.Edition 07. Prote cted by c o py rig ht . e nte is r o are listed here: eo h ut ra a c s s – Check needle bearing -arrow. It must be possible to guide the engine and gearbox together by hand until the engine flange and gearbox flange make contact all around.34 . in part or in wh ole. cial p is n mer m ot p o c erm or e t a itte v i r d p or tarnished blue. Nevertheless.2 – If it is not damaged. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E .Arrows point towards dowel sleeves es.40 Nm .0 l TFSI thi sd o cu m en ht rig py Co t.80 Nm ❑ If 18 mm insert -T10179is used: 65 Nm M10 . 2. Jetta 2005 ➤ .4 l TSI M12 .Golf Variant 2007 ➤ . Removing and installing gearbox 87 . is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng AG. Prote cted by c o py rig ht .3 Torque settings Engine: 1.9 l TDI. agen lksw Vo by AG.0 TDI. 2. Golf Variant 2010 ➤ .Edition 07. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit Engines: 1. in part or in w l purpos hole ercia .2010 6. C op yi 6. M10 .Edition 07.with 40 Nm + 90° further turn. Removing and installing start‐ er . Prote cted by c o p yri gh t . suspension links. – Renew all bolts on left assembly mounting.Controls. 27 . gr. 88 Rep. C op yi . Removing and installing subframe with steering box . is n m ot p om c r erm o e t a itte riv du p or nl f e g n n AG.to gearbox with bolts -1. Golf Variant 2010 ➤ . gr. 40 .40 Nm es.2010 M12 . Jetta 2005 ➤ . – First bolt bracket -A. ht rig py Co t. gr. Install subframe with steering box ⇒ Rep. antiroll bar.80 Nm ❑ If 18 mm insert -T10179is used: 65 Nm. in part or in w l purpos hole ercia . housing AG. Starter to gearbox ⇒ Rep.34 . Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss ility ab y li an pt ce rrectness of i t to the co nform spec at i h re o n wit in t his Continuation for all engines – First screw in all bolts by hand. agen lksw Vo by The bracket can be levered into the correct position with a screw‐ driver as bolts -2.Golf Variant 2007 ➤ . Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . – Tighten bolts -2. Note do c um en Assembly mounting bolts must be renewed. Subframe.to 60 Nm + 90°.are tightened. for example part of lifting tackle -2024 A. Oil will run out. Prote cted by c o py rig ht .2010 7 Transporting gearbox and securing to assembly stand Always secure heavy parts for transport.Edition 07. in part or in w l purpos hole ercia .222 A /12.and shackle -10 . Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s r te o iva r rp fo g n do c um en ht rig py Co t. un le AG.Golf Variant 2007 ➤ . is n m ot com pe rm itte d Example: securing gearbox to assembly stand. Transporting gearbox – Use appropriate lifting tools.. Golf Variant 2010 ➤ . Do not turn gearbox with breather downwards during transport or while on repair stand. Keep in mind that there is oil in the gearbox. es. C op yi 7. Gearbox may also be lifted with gearbox lifting tackle -3336. agen lksw Vo by AG. Transporting gearbox and securing to assembly stand 89 . Jetta 2005 ➤ . Jetta 2011 ➤ 6-speed dual clutch gearbox 02E .(not illustrated). or drip tray for workshop hoist -VAS 6208- es. it is often necessary to create access to filter. e. If the »old« filter is to remain in the gearbox. Jetta 2005 ➤ .G 1331- ♦ Used oil collection and extraction unit -V. Start engine and drain excess oil until oil level attains level of overflow pipe.Controls. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit ♦ Vehicle diagnostic tester . Golf Variant 2010 ➤ . please refer to the notes about oil ⇒ page 4 . Prote cted by c o p yri gh t. gr. Then re-install overflow pipe and »overfill« gearbox. agen lksw Vo by AG. Brief description First read the oil temperature. unscrew overflow pipe and drain oil. housing ht rig py Co t. When replacing oil filter. in part or in w l purpos hole ercia .G 1782. Special tools and workshop equipment required ♦ Torque wrench -V.g. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng AG. -VAS 5051- thi sd o cu m en 90 Rep. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . Air filter housing must be removed. C op yi .2010 8 Changing oil and filter and adjusting oil level This chapter shows you how the oil and filter are changed at the same time.A. If it is above 50 °C. let the gearbox cool off.Edition 07.Golf Variant 2007 ➤ . With engine stopped.A.34 . At start of work. in part or in w l purpos hole ercia . To change oil. ge i. To gearbox manufacture date „20 September 2004“.e.Edition 07.only.on near ⇒ pendulum support.2010 ♦ Adapter for filling oil -VAS 6262. only screw -A. Vehicle diagnostic tester is connected. oil temperature must not be above 50 °C.Golf Variant 2007 ➤ . Volkswagen AG es. gearboxes were constructed with 2 plugs. Prote cted by c o py rig ht . Therefore the Genuine part number for it can be found in the ⇒ Electronic parts catalogue „ETKA“ . r te o iva r rp fo g n do c um en 8. agen lksw Vo by AG. Selector lever in „P“. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . is n m ot com pe rm itte d un le ss e ris ho t au nte eo ra c ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s – Always renew oil seal -arrow-.or -VAS 6262 A- The oil is available as a Genuine part. which are »later«. Prerequisites • • • • • • Engine off. Changing oil and filter and adjusting oil level ht rig py Co t. It is important not to interchange these bolts. all supports in lifting platform at same height. b ara d n AG. V gu y are fitted with bolt -A. Noise insulation removed. Golf Variant 2010 ➤ . Jetta 2005 ➤ . Vehicle level. C op yi 91 . does Gearboxes built after 20th September swa not olk2004. C op yi . housing ht rig py Co t. – Position used oil collection and extraction unit -V.Golf Variant 2007 ➤ .under gearbox. r fo ng 92 Rep. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce urposes. But not yet. Jetta 2005 ➤ . Prote cted by c o py rig ht . in part or in wh ole.Do not start engine! Do not start engine until instructed to do so.1 Changing oil and filter Perform the following steps: – Please follow every one of the following instructions in the or‐ der given throughout the oil change. – – • Dual clutch gearbox Check fluid level If oil temperature is above 50 °C. cial p is n mer m ot p o c erm or e t a itte v i r d p un le rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en – Loosen filter housing through 7 turns. gr. Golf Variant 2010 ➤ . Jetta 2011 ➤ 6-speed dual clutch gearbox 02E .2010 8. – Now remove filter housing.A. the oil will flow from the filter housing back into the gearbox. – Connect vehicle diagnostic tester and identify the vehicle in Guided functions . let the gearbox cool off.34 .Controls.G 1782.or drip tray -VAS 6208.Edition 07. – Wait for 10 seconds. This way. AG. agen lksw Vo by AG. – Engine off . pe rm itte d – After inserting new filter element with -shoulder.Edition 07. Its length de‐ termines the oil level in the gearbox. – Add 5. To change bottles. Changing oil and filter and adjusting oil level 93 . tightening torque 3 Nm) is located in this hole. gr. 3 Nm. Prote cted by c o p yri gh t. r te o iva r rp fo g n A black plastic »overflow tube« (with 8 mm hexagon socket head bolt. in part or in w l purpos hole ercia .or drip tray -VAS 6208.above gearbox. Jetta 2011 ➤ h ut ra a 6-speed dual clutch gearbox 02E . – Position used oil collection and extraction unit -V. – Raise vehicle. ht rig py Co t.downwards. – Remove this oil pipe. – Continue to switch vehicle diagnostic tester until ⇒ DSG® oil temperature is displayed. is n m ot com Please wipe away any oil that overflows. 50 . Jetta o e o2005 ➤ . Golf Variant 2010 ➤ . close tap or hold adapter for filling oil -VAS 6262 A. C op yi Approximately 5 litres of oil will run out. 8.G 1782. Assembly overview .or -VAS 6262 A. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte s i r Golf Variant 2007 ➤ . un le AG.2010 c s s ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s – Remove inspection plug near pendulum support -arrow-. Shake oil cans before opening them. do c um en – Screw adapter -A. agen lksw Vo by – Screw overflow tube back in.under gearbox.noise insulation . tighten housing to 20 Nm.handtight into inspection hole.A.from -VAS 6262.es. – Remove noise insulation ⇒ Rep. AG.5 l of dual clutch gearbox oil. C op yi .or -VAS 6262 A. AG. is n m ot p om c r erm o e t a itte riv du p or nl f e g n rrectness of i t to the co nform spec at i h re o n wit in t his do c um en 94 Rep. re‐ move adapter for filling oil -VAS 6262. Please dispose of used oil properly ⇒ page 4 . Jetta 2011 ➤ 6-speed dual clutch gearbox 02E .Controls. Torque setting: 45 Nm – Switch off engine. Jetta 2005 ➤ . Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce – Install noise insulation⇒ Rep. housing ht rig py Co t. in part or in w l purpos hole ercia . gr. This concludes the oil and filter change.Edition 07.2010 – Now start engine. – When excess oil has run out (when it begins only to drip). gr. es.34 . – Depress brake pedal and select each selector lever position for about 3 seconds. Prote cted by c o p yri gh t.with engine running. The oil level in the gearbox is correctly set. Assembly overview noise insulation . – Let surplus oil drain out. agen lksw Vo by AG. Golf Variant 2010 ➤ . Do not switch off engine! When the oil temperature has reached 35 °C to 45 °C: – Disconnect quick-release coupling of adapter for filling oil VAS 6262 A. Move selector lever to position »P« po‐ sition.Golf Variant 2007 ➤ . Oil which has run out cannot be filled again. 50 .and install plug with new seal. no repairs can be made to gears and shafts urposes. Jetta 2005 ➤ . in part or in wh ole. C op yi 95 .2010 35 – 1 Gears. Currently.Edition 07.Golf Variant 2007 ➤ . Prote cted by c o py rig ht . Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en r fo ng 1. no repairs can be made to gears and shafts ht rig py Co t. Golf Variant 2010 ➤ . agen lksw Vo by AG. shafts Currently. cial p is n mer m ot p o c erm or e t a itte v i r d p un le AG. C op yi . is n m ot com pe rm itte d rrectness of i t to the co nform spec a t i h re o n in wit thi s r te o iva r rp fo g n do c um en 96 Rep. If the differential bevel gears turn. Golf Variant 2010 ➤ . it is difficult to reinstall the bolts.2010 39 – 1 Final drive . Jetta 2005 ➤ . gr.differential ht rig py Co t.Golf Variant 2007 ➤ .Final drive . Prote cted by c o p yri gh t . in part or in w l purpos hole ercia .Edition 07. 1. agen lksw Vo by AG.A.differential Renewing seals for flange shaft or stub shaft Do not remove both securing bolts in left and right flange shafts or right stub shaft at the same time. Jetta 2011 ➤ 6-speed dual clutch gearbox 02E .1 Renewing oil seal for left flange shaft Special tools and workshop equipment required ♦ Multipurpose tool -VW 771♦ Puller hooks -VW 771/37♦ Thrust piece -3305♦ Torque wrench -V.G 1332♦ Sealing grease -G 052 128 A1un le n AG.39 .A. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss ility ab y li an pt ce es.G 1331♦ Torque wrench -V. 40 . Renewing seals for flange shaft or stub shaft AG. gr. Repairing drive shafts. Removing and installing drive shafts . agen lksw Vo by – Remove left drive shaft ⇒ Rep. Wheel housing liner. Assembly overview .noise insulation . – Place drip tray for workshop hoist -VAS 6208. Jetta 2005 ➤ . 66 . – Pull out flange shaft together with compression spring.1 Removing Perform the following steps: – Remove left wheel.. 1. 50 . Golf Variant 2010 ➤ . ht rig py Co t.1. – Pull out flange shaft oil seal using multi-purpose tool -VW 771and puller hooks -VW 771/37.under gearbox. is n m ot com pe rm itte d rrectness of i t to the co nform spec a t i h re o n in wit thi s 1. C op yi – Remove lower part of front left wheel housing liner ⇒ Rep. do c um en – Remove flange shaft securing bolt by screwing 2 bolts into flange and counterholding flange shaft with a lever.Golf Variant 2007 ➤ . gr. in part or in w l purpos hole ercia . Removing and installing wheel hous‐ ing liner .2010 a es n ksw ♦ Drip tray for workshop hoist -VAS 6208un le ss ol yV db e ris tho au ot g ua ran tee or ac ility ab y li an pt ce es. Prote cted by c o py rig ht . 1. Volkswagen AG gen AGgearbox 02E d 6-speed dual clutch -o Edition 07. gr. r te o iva r rp fo g n – Remove noise insulation ⇒ Rep.1. Jetta 2011 ➤ . 97 .2 Installing – Lightly oil outer circumference of new oil seal. When doing this.2010 olksw agen AG AG. agen lksw Vo by – Change oil for dual clutch gearbox ⇒ page 90 . press flange shaft against gearbox so that bolt engages in thread. is n m ot com pe rm itte d un le rrectness of i t to the co nform spec a t i h re o n in wit thi s – Drive in new seal to stop. in part or in w l purpos hole ercia .Golf Variant 2007 ➤ . 50 . – Install left wheel housing liner⇒ Rep. gr.noise insulation . – Install left drive shaft ⇒ Rep. Removing and installing wheel housing liner . ht rig py Co t. y Vo gu b ed ris o th au ss ara nte e or ac ility ab y li an pt ce es. gr. Prote cted by 1.-arrow-. Noise insulation. Jetta 2005 ➤ . r te o iva r rp fo g n do c um en – Install left wheel ⇒ Rep. – Tighten new countersunk bolt to 30 Nm. gr. C op yi . 40 . V – Half-fill space between sealing lip and dust lip of n new seal with does wage s k not l sealing grease -G 052 128. gr. gr.differential c o p yri gh t . AG. 66 .Edition 07. – Insert flange shaft. – Install noise insulation⇒ Rep. Removing and installing drive shafts . As‐ sembly overview . Repairing drive shafts.Final drive . Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . Torque settings for mounting wheels . being careful not to cant seal. 44 .2 Renewing seals for right flange shaft or stub shaft Special tools and workshop equipment required ♦ Drift sleeve -3158- 98 Rep. Golf Variant 2010 ➤ . Wheel housing.39 . gr. C op yi 99 . – Remove noise insulation⇒ Rep. is n m ot com pe rm itte d un le rrectness of i t to the co nform spec a t i h re o n in wit thi s ♦ Torque wrench -V. Jetta 2005 ➤ . Golf Variant 2010 ➤ . Removing and installing drive shafts .Edition 07.Golf Variant 2007 ➤ . Renewing seals for flange shaft or stub shaft ht rig py Co t. agen lksw Vo by AG. gr. Noise insulation. Vehicles with intermediate shaft 1. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce es.G 1332♦ Drip tray for workshop hoist -VAS 6208- r te o iva r rp fo g n do c um en ♦ Sealing grease -G 052 128 A1- ♦ All-purpose grease -G 052 735- 1. in part or in w l purpos hole ercia . Jetta 2011 ➤ 6-speed dual clutch gearbox 02E .2010 ♦ Torque wrench -V. Prote cted by c o py rig ht . 50 .A. – Remove right drive shaft ⇒ Rep.1 Removing Perform the following steps: – Remove right wheel. – Remove drive shaft heat shield from engine -arrows-.G 1331AG. 40 . As‐ sembly overview . Repairing drive shafts.A. if fitted.2.noise insulation . Continuation for all vehicles – Place drip tray for workshop hoist -VAS 6208.. press stub shaft or flange shaft against gearbox so that bolt engages in thread. Golf Variant 2010 ➤ . When doing this.from bearing bracket -C. – Insert stub shaft or flange shaft.-arrows. Vehicles with intermediate shaft c o p yri gh t. un le AG. – Remove securing bolts -arrow. AG. unbolt intermediate shaft -B. in part or in wh ole.39 . cial p is n mer m ot p o c erm or e t a itte v i r d p – Half-fill space between sealing lip and dust lip of new seal with sealing grease -G 052 128.2.under gearbox. – Pull out stub shaft or flange shaft together with compression spring. 1. Prote cted by ht rig py Co t. C op yi .differential agen lksw Vo by – Grease splines of stub shaft with grease for clutch plate splines -G 000 100. 100 Rep.2010 – After removing right drive shaft -A-. – Pry seal out using assembly lever.Edition 07. being careful not to cant seal.Golf Variant 2007 ➤ . gr. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u circumference of new oil seal. r fo ng – Renew O-ring of stub shaft.2 Installing – Lightly oil outer urposes.and pull out stub shaft of gearbox. – Tighten new countersunk bolt to 30 Nm. ra a c s s ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en – Drive in new seal to stop.Final drive .-arrow-.for stub shaft or flange shaft. Jetta 2005 ➤ . Jetta 2011 ➤ 6-speed dual clutch gearbox 02E . ot g ua ran tee or ac ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit – Install right wheel ⇒ Rep. Golf Variant 2010 ➤ . Repairing drive shafts. Prote cted by c o py rig ht . – Change oil for dual clutch gearbox ⇒ page 90 . gr. As‐ sembly overview . gr. Renewing seals for flange shaft or stub shaft ht rig py Co t.Golf Variant 2007 ➤ . V 02E does 07. Jetta 2011 ➤ olkswagen AG en AG.Edition ag ksw n – Guide intermediate shaft -B. – Install noise insulation⇒ Rep. thi sd o cu m en 1. 50 . is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng – Bolt intermediate shaft to bearing bracket to specified torque -arrows. 40 . Jetta 2005 ➤ . in part or in w l purpos hole ercia . gr.2010 6-speed dual clutch gearbox . Torque settings for mounting wheels . agen lksw Vo by AG. Removing and installing drive shafts . Repairing drive shaft. 40 . Noise insulation.through bearing stub shaft of gearbox. 44 . ol yV db e bracket -Cris onto ho ut a ss Continuation for all vehicles es. gr.noise insulation . C op yi 101 . – Install right drive shaft ⇒ Rep. Removing and installing drive shafts .⇒ Rep.