Volkswagen Golf Variant 2007 Repair Manual
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Volkswagen Golf Variant 2007 Repair Manual

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Service
Repair Manual
Golf Variant 2007 ➤
Golf Variant 2010 ➤
Jetta 2005 ➤
Jetta 2011 ➤
7-Speed Dual Clutch Transmission 0AM
Edition 09.2015
Service Department. Technical Information

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Summary of Contents for Volkswagen Golf Variant 2007

  • Page 1 Service Repair Manual Golf Variant 2007 ➤ Golf Variant 2010 ➤ Jetta 2005 ➤ Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM Edition 09.2015 Service Department. Technical Information...
  • Page 2 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 © 2016 Volkswagen AG, Wolfsburg D4B8035092C...

  • Page 3: Table Of Contents

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Contents 00 - General, Technical Data ..........
  • Page 4 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Transmission, Removing and Installing, Jetta from MY 2005, Golf Wagon from MY 2007 and Golf Wagon from MY 2010 ..........127 Transmissions with Different Output Shafts .

  • Page 5: General, Technical Data

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 00 – General, Technical Data Transmission Identification (Edition 09.2015) KHN - Transmission Code Refer to ⇒...

  • Page 6: Overview - Transmission

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Overview - Transmission The 7-speed DSG® transmission 0AM has 5 shafts. Two input shafts and three output shafts.

  • Page 7: Engine Codes, Engine Allocation

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Engine Codes, Engine Allocation Use the transmission code if a repair requires replacement parts. Allocation: Transmission Codes for Gasoline Engines...

  • Page 8: Capacities

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Capacities The 7-Speed DSG® transmission has two separate, different fluid systems. One for the transmission fluid -arrow A- and one for the hydraulic fluid -arrow B-.

  • Page 9: Safety Precautions

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Safety Precautions ⇒ “5.1 General Safety Precautions”, page 5 ⇒ “5.2 Safety Precautions when Working on Vehicles with Start/ Stop System”, page 5...

  • Page 10: Safety Precautions During Road Test With Testing Equipment

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Safety Precautions during Road Test with Testing Equipment Performing road tests while using testing equipment:...

  • Page 11: Tow Starting And Towing Notes

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Tow Starting and Towing Notes Caution Risk of destroying the transmission. ♦ When towing the vehicle, move the selector lever to “N”.

  • Page 12: General Repair Information

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 General Repair Information ⇒ “7.1 Tools”, page 8 ⇒ “7.2 Transmission”, page 8 ⇒ “7.3 Working with Vehicle Diagnostic Testers ”, page 13...
  • Page 13 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Always make sure that no dirt enters an »open« transmission. ♦ Do not run the engine when the cover is removed from the transmission or when there is no transmission fluid in the transmission.
  • Page 14 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Some Vehicles Have A Cover Over the Engaging Levers The cover prevents dirt from getting in.
  • Page 15 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Selector Mechanism Similar to an automatic transmission, the selector lever position is no longer transmitted mechanically to the transmission via the selector lever cable and the multifunction transmission range switch (drive position sensor).
  • Page 16 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 ♦ O-rings, gaskets and seals must always be replaced. ♦ The seals for the stub shaft or the flange shaft and drive axle are also called shaft seals.

  • Page 17: Working With Vehicle Diagnostic Testers

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Working with Vehicle Diagnostic Testers ⇒ “7.3.1 Adapting Installation Information”, page 13 ⇒ “7.3.2 Mandatory Reporting Measurements, Reading”, page 13 ⇒...
  • Page 18 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 ♦ If “Guided Fault Finding” requests it ♦ after having corrected a fault stored in the DTC memory ♦...

  • Page 19: Clutch

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 30 – Clutch Dual Clutch, Removing and Instal‐ ling, through Transmission Produc‐ tion Date 05/2011 Transport the Transmission and Secure to the Assembly Stand.
  • Page 20 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 1 - Circlip ❑ Always replace after re‐ moving 2 - Hub 3 - Circlip ❑...

  • Page 21: Dual Clutch, Removing, Through Transmission Production Date 05/2011

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 15 - Dual Clutch ❑ Removing. Refer to ⇒ “1.2 Dual Clutch, Removing, through Transmission Production Date 05/2011”, page 17 ❑...
  • Page 22 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Turn the transmission on the engine/transmission holder with the clutch facing up. Refer to ⇒ “6 Transmission, Transporting and Securing To Assembly Stand”, page 191...
  • Page 23 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Position the Support Bridge - T1032- parallel to the transmis‐ sion flange, as illustrated.

  • Page 24: K 1" And "K 2" Clutch Engaging Bearing Position, Adjusting, Transmission Production Date Through 05/2011

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Remove the small engaging bearing. – Remove the large engaging lever. – Remove the bolts and remove the engaging lever with the bracket.
  • Page 25 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Caution The following components must also be replaced if the dual clutch is replaced: ♦ Both engaging levers with engaging bearing.
  • Page 26 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 1 - Small Engaging Lever for »K 2« ❑ Always replace when replacing the dual clutch 2 - Shim for »K 2«...
  • Page 27 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Step 1: Prepare to Measure the Dual Clutch – Insert the engaging lever mount. – Install the small engaging lever with the bracket and tighten with two new screws.
  • Page 28 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Step 2: Determine the Dimension “B” for Clutch “K 1” and “K 2”. – Place Ruler (2 pc.) - T40100- across the end of the shaft on the transmission flange.
  • Page 29 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Measure dimension “B 2 ” on the opposite side of the locking ring. Note Do not measure on the end of the locking ring.
  • Page 30 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Place the Digital Depth Gauge - 300mm - VAS6594- on top of the Ruler (2 pc.) - T40100- and position the depth slide on the outer input shaft.
  • Page 31 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – On the opposite side, measure the dimension “A 1 b ” on the Setting Tool - Release Bearing - T10374- .
  • Page 32 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Step 6: Measure the Clutch Tolerance for “K 1” Clutch. – Read the clutch tolerance value on the new clutch.
  • Page 33 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Step 8: Determine Dimension “A 2” for “K 2” Clutch Engaging Bearing – Only insert the small engaging bearing.
  • Page 34 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Place the Setting Tool - Release Bearing - T10374- with the large opening upward on the small engaging bearing.
  • Page 35 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – On the opposite side, measure the dimension “A 2 b ” on the Setting Tool - Release Bearing - T10374- .
  • Page 36 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Step 11: Measure the Clutch Tolerance for “K 2” Clutch. – Read the clutch tolerance value on the new clutch.

  • Page 37: Dual Clutch, Installing, Transmission Production Date Through 05/2011

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Dual Clutch, Installing, Transmission Production Date through 05/2011 Special tools and workshop equipment required ♦ Support Bridge - T10323- ♦...
  • Page 38 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Install the small engaging lever with the bracket. Note Only a few »older« transmissions do not have a bracket.
  • Page 39 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Insert the small engaging bearing -1- with the measured shim -2- for the “K 2” clutch.
  • Page 40 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Turn back the spindle on the Puller - Clutch - T10373- . Caution Danger of causing damage to the clutch adjusting tool.
  • Page 41 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Turn the clutch against the Puller - Clutch - T10373- by hand without using any other tools so that it can move into its oper‐...
  • Page 42 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Insert the locking ring -arrow-. • The end of the locking ring must face the »nose« on the clutch.
  • Page 43 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Note If an engaging lever is moving back and forth, then the shim ♦ is not in its correct position.

  • Page 44: Dual Clutch, Removing And Installing, From Transmission Production Date 06/2011

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Dual Clutch, Removing and Instal‐ ling, from Transmission Production Date 06/2011 Dual Clutch, Removing and Installing, through Transmission Pro‐...
  • Page 45 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 1 - Engaging Lever Support ❑ For the large engaging lever “K 1” ❑ Is not replaced 2 - Ball Stud ❑...

  • Page 46: Dual Clutch, Removing, Transmission Production Date From 06/2011

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 13 - Bolts ❑ 8 Nm +90° ❑ Always replace after removing 14 - Guide Sleeve Lower Section ❑...
  • Page 47 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Turn the transmission on the engine/transmission holder with the clutch facing up. Note The clutch is removed upward. The Mechatronic stays on the transmission.
  • Page 48 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Position the Support Bridge - T1032- parallel to the transmis‐ sion flange, as illustrated.

  • Page 49: K 1" And "K 2" Clutch Engaging Bearing Position, Adjusting, Transmission Production Date From 06/2011

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Remove the »large« engaging lever with the »small« engaging bearing. Note The guide sleeve upper section cannot be removed or installed separately.
  • Page 50 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Note It is not necessary to perform an adjustment if all the compo‐ ♦ nents mentioned are only removed and reinstalled.
  • Page 51 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 ❑ Removed and installed together with the guide sleeve lower section 7 - Small Engaging Lever for “K 2”...
  • Page 52 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Install the »new« ball stud by hand. Use a plastic hammer and drift gently, if necessary.
  • Page 53 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Place the Digital Depth Gauge - 300mm - VAS6594- on top of the Ruler (2 pc.) - T40100- and position the depth slide on the outer input shaft.
  • Page 54 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Remove the circlip from the outer input shaft and dispose of WARNING Do not re-use the locking ring.
  • Page 55 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Place the Digital Depth Gauge - 300mm - VAS6594- on top of the ruler and position the depth slide on the outer input shaft.
  • Page 56 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Step 4: Determine the Clutch Tolerance for the “K 1” Clutch. – Read the clutch tolerance value on the new clutch.
  • Page 57 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Remove the Gauge - Clutch Bearings - T10466- and large en‐ gaging lever. Step 6: Determine Dimension “A 2” for “K 2” Clutch Engaging...
  • Page 58 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Hold the guide sleeve upper section with one hand. Turn the guide sleeve lower section in direction of -arrow- with the other hand until the sleeve moves freely.
  • Page 59 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Install the »small« engaging bearing without the shim. WARNING Do not install the shim.
  • Page 60 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Position the depth slide on the Gauge - Clutch Bearings - T10466- , as illustrated.
  • Page 61 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Step 8: Determine the Clutch Tolerance for the “K 2” Clutch. – Read the clutch tolerance value on the new clutch.

  • Page 62: Dual Clutch, Installing, Transmission Production Date From 06/2011

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Dual Clutch, Installing, Transmission Production Date from 06/2011 Special tools and workshop equipment required ♦ Support Bridge - T10323- ♦...
  • Page 63 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Install the »small« engaging lever with the upper and lower sections of the guide sleeve. Install new bolts and tighten them.
  • Page 64 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Install the clutch in the transmission using the Puller - Clutch - T10373- as shown.
  • Page 65 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Turn the clutch against the Puller - Clutch - T10373- by hand without using any other tools so that it can move into its oper‐...
  • Page 66 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Turn the clutch by hand. It should turn without any problem. Note Remove the clutch if it is difficult to turn or if the it grinds against ♦...

  • Page 67: Clutch-Side Seals, Removing And Installing

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Clutch-Side Seals, Removing and In‐ stalling Replacing the Input Shaft Seal There are 2 seals in the transmission on the clutch side. It is pos‐...
  • Page 68 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Remove the outer seal. – Drive in the outer, »new« seal flush to the clutch housing using a plastic mallet.
  • Page 69 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Drive in the »new« seal all the way. – Dual Clutch, Installing: ♦ Through Transmission Production Date 05/2011. Refer to ⇒...

  • Page 70: Special Tools

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Special Tools Special tools and workshop equipment required ♦ Support Bridge - T10323- Rep. Gr.30 - Clutch...
  • Page 71 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 ♦ -T10356/5- from the Subframe Bushing Assembly Tool Kit - T10356- ♦ Puller - Clutch - T10373- ♦...
  • Page 72 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 ♦ Puller - Shaft Seal - T10420- ♦ Seal Installer - Shaft Seal - T10421- ♦...
  • Page 73 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 ♦ Ruler (2 pc.) - T40100- ♦ Press Piece - 60mm - VW415A- ♦ Engine Bung Set - VAS6122- ♦...

  • Page 74: Controls, Housing

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 34 – Controls, Housing Transmission Fluid, Replacing Special tools and workshop equipment required ♦ Used Oil Collection and Extraction Unit - SMN372500- ♦...
  • Page 75 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Make a mark on the bleed pipe, dimension -a-, and cut it, with for example the Brake Line Tool Kit - Pipe Cutter - VAS6056/2- .
  • Page 76 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Remove the battery and the battery tray -arrows-. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Battery, Remov‐...
  • Page 77 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Note Use the Oil Filler - Adapter 6 - VAS6262/6- if the container thread does not fit on the Adapter For Oil Filling - VAS6262A- .

  • Page 78: Selector Mechanism

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Selector Mechanism WARNING Move the selector lever into “P” and set the parking brake be‐...
  • Page 79 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 1 - Shift Cover with Handle ❑ Do not remove the han‐ dle unnecessarily. Only the cover must be un‐...

  • Page 80: Selector Lever Cable, Removing And Installing, Through 02/2009

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 7 - Gearshift Housing ❑ With seal 8 - Selector Lever Cable ❑ Do not grease the selector lever cable.
  • Page 81 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Note Use pliers to remove the lock washer. Do not use a sharp- ♦ edged lever. Otherwise the selector lever cable could get damaged.
  • Page 82 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – If equipped, remove nuts -1 and 2- and remove the rear tunnel brace. – Disengage the center muffler and the rear muffler from the re‐...
  • Page 83 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 The -shift housing- is pushed forward slightly on the selector lever cable. 2. Selector Mechanism...
  • Page 84 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 The locking strap must be pushed forward in order to remove the selector lever cable -arrow 1-.
  • Page 85 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 For Clarity – Remove the selector lever cable. Remove the selector lever cable from the selector housing.
  • Page 86 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – When installing, make sure the selector lever cable is routed correctly. If the heat shield underneath is bent, there will be noises. The selector lever cable will then »flap«...
  • Page 87 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Install the selector housing. 2. Selector Mechanism...

  • Page 88: Selector Mechanism Overview, From 03/2009

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Install the heat shield -1- under the selector mechanism and attach with the lock washers -2 and 3-.

  • Page 89: Selector Mechanism, Removing And Installing, Vehicles From 03/2009

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 ❑ Do not grease the selector lever cable. ❑ Removing and Installing. Refer to ⇒ “2.4 Selector Mechanism, Removing and Installing, Vehicles from 03/2009”, page 85 ❑...
  • Page 90 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Move the selector lever into “P”. – Remove the selector lever handle and disconnect the con‐...
  • Page 91 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Note Use pliers to remove the lock washer -1-. Do not use a sharp- ♦...
  • Page 92 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – If necessary remove the exhaust system bracket from the subframe -arrows-. – Tie up the front exhaust pipe.
  • Page 93 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Remove the nuts -arrows- in the vehicle interior. – Remove the bracket -A-, if equipped.
  • Page 94 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 2.4.2 Selector Mechanism without Selector Housing, Removing and Installing Brief Description The selector mechanism and the selector lever cable must be separated from each other.
  • Page 95 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Remove the lock washer -1- from the selector lever cable. Always replace the circlip on the selector lever cable.
  • Page 96 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Pull the selector mechanism and selector lever cable out of the center tunnel. Make sure the cord is pull through far enough so that it can reached from inside the engine com‐...

  • Page 97: Selector Lever Cable, Checking

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Attach the selector mechanism to the selector housing with four bolts. – Install the center console. Refer to ⇒ Body Interior; Rep. Gr.

  • Page 98: Selector Lever Cable, Adjusting

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 If the lock washer is removed, then a »new« lock washer must always be installed.
  • Page 99 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 The selector lever on the transmission must pushed »all the way toward the right side of the vehicle«, in the direction of the selector lever cable bracket.

  • Page 100: Selector Lever, Emergency Release

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Selector Lever, Emergency Release Note Do not remove the handle. – Unclip the shift cover and hold it to the side.
  • Page 101 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Handle with the Button on the Side – Pull the button out of the handle just far enough until there is a small gap can is visible between the handle and the button.
  • Page 102 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Handle with the Button on the Side • The button inside the handle is pulled out and if necessary is protected from getting pushed in again.

  • Page 103: Button In Handle, Moving Into Installation Position

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Note A new handle is delivered with an assembly fastener. Remove the retainer just before installing.
  • Page 104 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Move the Handle »with« an Assembly Fastener into the Installa‐ tion Position: When using an assembly fastener, make sure that it has an eye -arrow- at the front.

  • Page 105: Selector Mechanism, Checking

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Push the small lever -1- for the pull rod into the groove -2- with a screwdriver.
  • Page 106 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 The ignition and Lights Must Be Turned On The respective symbol is being lit up in the selector mechanism cover.

  • Page 107: Dsg Transmission Mechatronic J743

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 DSG Transmission Mechatronic - J743- ⇒ “3.1 DSG Transmission Mechatronic J743 Safety Precautions”, page 103 ⇒...

  • Page 108: Overview - Mechatronic

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 WARNING The system is under pressure. The DSG Transmission Mechatronic - J743- has a pressure reservoir that can hold a system pressure up to 60 bar.

  • Page 109: Dsg Transmission Mechatronic J743 , Removing With Transmission Installed

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Pay attention to the vent when handling the Mechatronic. – When doing assembly work on the Mechatronic, please re‐...
  • Page 110 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Note The clutch is self-adjusting. Vibrations can affect the adjusting ♦ tool. Also when the Mechatronic is removed, the »abrupt pull‐...
  • Page 111 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Some Vehicles have A Cover Over the Engaging Levers. The cover prevents dirt from getting in.
  • Page 112 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Remove the cap -arrow- from the Mechatronic vent. Seal so that it is oil-tight using a clean plug taken from Engine Bung Set - VAS6122- .
  • Page 113 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Insert the Assembly Lever - Mechatronic - T10407- to the right of this. 3. DSG Transmission Mechatronic J743...
  • Page 114 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Insert until the groove aligns with the housing rib -arrow-. Rep. Gr.34 - Controls, Housing...
  • Page 115 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Do not go further. – The »rear side« of the Assembly Lever - Mechatronic - T10407- should rest completely on the transmission housing.
  • Page 116 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Turn the Assembly Lever - Mechatronic - T10407- counter-clock‐ wise. Then press the engaging lever away from the plungers direction of the -arrow-.
  • Page 117 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Note Leave the Assembly Lever - Mechatronic - T10407- inserted be‐ tween the engaging lever and transmission housing after remov‐...
  • Page 118 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 For clarity, the transmission is shown here again from the side. The Mechatronic must be removed. The cover should not be re‐...

  • Page 119: Dsg Transmission Mechatronic J743 , Moving Into "Removal Position" By Hand

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 It may not be possible to remove the Mechatronic. In this case, the gear selector is »caught« at the »upper left side« on the trans‐...
  • Page 120 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Sometimes it may not be possible to remove the Mechatronic. In this case, the gear selector will get »caught« at the »top left side«...
  • Page 121 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Remove the lock washer in the direction of the -arrow-. Always replace the circlip on the selector lever cable.
  • Page 122 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Push the shift fork to the side through the opening in direction of -arrow-.

  • Page 123: Dsg Transmission Mechatronic J743 , Installing

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Press the selector lever cable onto the ball head on the se‐ lector lever again and install the new lock washer.
  • Page 124 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Check each of the 4 shift forks by hand. Each Shift Fork has 3 Settings: »gear engaged - neutral - gear engaged«.
  • Page 125 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Install the Guide Bolt - Mechatronic - T10406- hand-tight. Make sure all 4 gear positioners stick out 25 mm -a-.
  • Page 126 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Check the seal on the Mechatronic. The seal must be fastened all around. – Pay attention to the Transmission Input Speed Sensor 3 - G641- .
  • Page 127 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Make sure the plungers fit correctly in the engaging lever socket when doing so.
  • Page 128 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Remove the plug and mount the vent cap -arrow-. Caution Danger of causing damage to transmission components.

  • Page 129: Overview - Shift Forks With Mechatronic Removed

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – If removed, install the charge air or coolant hoses. – Install the battery and the battery tray. Refer to ⇒ Electrical Equipment;...
  • Page 130 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 1 - Gear 2 - Gear 3 - Gear 4 - Gear 5 - Gear...

  • Page 131: Transmission, Removing And Installing, Jetta From My 2005, Golf Wagon From My 2007 And Golf Wagon From My 2010

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Transmission, Removing and Instal‐ ling, Jetta from MY 2005, Golf Wagon from MY 2007 and Golf Wagon from MY 2010 Information for transmissions with different output shafts.
  • Page 132 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 ♦ Transmission Support - Mounting Plate 59 - 3282/59- ♦ Engine Support Bridge - Engine Support Feet - 10-222A/8- ♦...
  • Page 133 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Remove the battery and the battery tray. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Battery, Removing and In‐...
  • Page 134 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Note Use pliers to remove the lock washer. Do not use a sharp- ♦ edged lever. Otherwise the selector lever cable could get damaged.
  • Page 135 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 One bolt is located inside the starter opening. In place of an 18 mm nut, the Socket - Xzn 14 - T10061- can also be used.
  • Page 136 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Remove all of the front brackets from the transmission. – Remove the pendulum support.
  • Page 137 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Both drive axles are attached to the suspension strut with the Tensioning Strap - T10038- .
  • Page 138 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Support the engine and transmission with the Engine Support Bridge - 10-222A- but do not lift.

  • Page 139: Transmission, Removing, Vehicles With 1.6L/75 Kw Mpi Engine

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Mount both remaining mounting elements on the transmission as shown. While doing this, place the drift plate under the transmission housing and not under the Mechatronic.
  • Page 140 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 ♦ Engine Support Bridge - 10-222A- ♦ Engine Support Bridge - Engine Support 3 - 10-222A/3- ♦...
  • Page 141 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Note Use pliers to remove the lock washer. Do not use a sharp- ♦ edged lever. Otherwise the selector lever cable could get damaged.
  • Page 142 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 One bolt is located inside the starter opening. In place of an 18 mm nut, the Socket - Xzn 14 - T10061- can also be used.
  • Page 143 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Remove all of the front brackets from the transmission. – Remove the pendulum support.
  • Page 144 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Both drive axles are attached to the suspension strut with the Tensioning Strap - T10038- .
  • Page 145 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Attach the Engine Support Bridge - Gearbox Bracket - T10346- to the rear hole of the three locating holes for the battery tray.
  • Page 146 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Lightly pretension the engine/transmission assembly and En‐ gine Support Bridge using the spindles. Remove all bolts -1 and 2- from the transmission bracket.

  • Page 147: Transmission, Removing, Vehicles With 1.9L 77 Kw Tdi Pd Engine

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Note Always replace the needle bearing -arrow- after separating the ♦ engine and transmission. If the needle bearing in the crankshaft is damaged, the gears ♦...
  • Page 148 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 The battery, the air filter and the starter are removed »from above«. The noise insulation under the engine/transmission, the lower cover in the left front wheel housing and the pendulum support are removed »from below«.
  • Page 149 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Note Use pliers to remove the lock washer. Do not use a sharp- ♦ edged lever. Otherwise the selector lever cable could get damaged.
  • Page 150 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Remove the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Noise Insulation .
  • Page 151 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Remove the left control arm from the ball joint. – Move the left drive axle into the wheel housing and on the lon‐...
  • Page 152 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Remove the pendulum support. – Remove the engine cover from the cylinder head. – If there are hose and cable connections located near the en‐...
  • Page 153 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 To remove the transmission 0AM, the Transmission Support - 3282- is equipped with the Transmission Support - Mounting Plate 59 - 3282/59- and positioned on the Engine and Gearbox Jack - VAS6931- .

  • Page 154: Transmission, Removing, Vehicles With 1.6L/77 Kw Tdi Cr Engine

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Note Always replace the needle bearing -arrow- after separating the ♦ engine and transmission. If the needle bearing in the crankshaft is damaged, the gears ♦...
  • Page 155 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 The noise insulation under the engine/transmission, the lower cover in the left front wheel housing and the pendulum support are removed »from below«.
  • Page 156 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Note Use pliers to remove the lock washer. Do not use a sharp- ♦ edged lever. Otherwise the selector lever cable could get damaged.
  • Page 157 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Remove the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Noise Insulation .
  • Page 158 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Remove the left control arm from the ball joint. – Move the left drive axle into the wheel housing and on the lon‐...
  • Page 159 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Remove the pendulum support. – Disconnect any hoses and cables in the area of the Engine Support Bridge - 10-222A- lifting eyes on the engine.
  • Page 160 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Remove all bolts -1 and 2- from the transmission bracket. – Then lower the engine/transmission slightly using the Engine Support Bridge - 10-222A- spindle so that the transmission bracket can be removed.

  • Page 161: Transmission, Installing, Jetta From My 2005, Golf Wagon From My 2007, Golf Wagon From

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Note Always replace the needle bearing -arrow- after separating the ♦ engine and transmission. If the needle bearing in the crankshaft is damaged, the gears ♦...
  • Page 162 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Some Vehicles have A Cover Over the Engaging Levers. The cover prevents dirt from getting in.
  • Page 163 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Continuation for All Transmissions Note Always replace the needle bearing -arrow- after separating the ♦...
  • Page 164 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Install the left subframe mount as follows: – Replace all bolts -1 and 2- for the left subframe mount.

  • Page 165: Transmission To Engine" Tightening Specifications And Subframe Mount Information

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Pay special attention to both vent caps -arrows- when instal‐ ling the starter. – Always adjust selector lever cable. Refer to ⇒...
  • Page 166 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Left Assembly Mounts – Replace all bolts -1 and 2- for the left subframe mount.
  • Page 167 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 M12 - Bolt ❑ 80 Nm ❑ When using the Insert Tool - 18 mm - T10179- : 65 Nm.
  • Page 168 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 4.7.2 1.9L/77 kW TDI PD Engine Note ♦ The -arrows- point to the alignment sleeves in the engine.
  • Page 169 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 4.7.3 1.6L/77 kW TDI Common Rail Engine Note ♦ The -arrows- point to the alignment sleeves in the engine.

  • Page 170: Transmission, Removing And Installing, Jetta From My 2011

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Transmission, Removing and Instal‐ ling, Jetta from MY 2011 ⇒ “5.1 Transmission, Removing, Jetta 2011 with 1.4L/90 kW TFSI Engine and 1.4L/118 kW TSI Engine”, page 166...
  • Page 171 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Remove the battery and the battery tray. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Battery, Removing and In‐...
  • Page 172 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Release the connector lock on the Mechatronic by pulling in the direction of the -arrow- and remove the connector.
  • Page 173 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 One bolt is located inside the starter opening. In place of an 18 mm nut, the Socket - Xzn 14 - T10061- can also be used.
  • Page 174 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Remove all of the front brackets from the transmission. – Remove the pendulum support.
  • Page 175 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Both drive axles are attached to the suspension strut with the Tensioning Strap - T10038- .
  • Page 176 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Remove the bolts -arrows- for the left and right lock carrier retaining brackets. – Remove the lower mounts on the Engine Support Bridge - En‐...
  • Page 177 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Push the Engine Support - Basic Set - Rail with Holes - T40091/2- -7- with the Engine Support - Supplement Kit - Mount - T40093/5- -8- in the Engine Support - Supplement Kit - Movable Joint - T40093/4- -4-.
  • Page 178 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Remove all bolts -1 and 2- from the transmission bracket. – Slightly lower the engine and transmission using the Engine Support Bridge - 10-222A- spindles so that the transmission bracket can be removed.

  • Page 179: Transmission, Removing, Jetta 2011 With 1.6L/77 Kw Tdi Cr Engine

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Note Always replace the needle bearing -arrow- after separating the ♦ engine and transmission. If the needle bearing in the crankshaft is damaged, the gears ♦...
  • Page 180 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 The noise insulation under the engine/transmission, the lower cover in the left front wheel housing and the pendulum support are removed »from below«.
  • Page 181 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Note Use pliers to remove the lock washer. Do not use a sharp- ♦ edged lever. Otherwise the selector lever cable could get damaged.
  • Page 182 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Loosen the left front wheel bolts. – Raise the vehicle. – Remove the left front wheel.
  • Page 183 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Remove the left control arm from the ball joint. – Move the left drive axle into the wheel housing and on the lon‐...
  • Page 184 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Remove the pendulum support. – Remove the plenum chamber cover. Refer to ⇒ Body Exterior;...
  • Page 185 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – First slide the Moveable Joints -2- onto the Square Pipe from the Engine Support Bridge - 10-222A- .
  • Page 186 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Pretension the engine/transmission sub-assembly using the spindles, but do not lift it. Remove all bolts -1 and 2- from the transmission bracket.

  • Page 187: Transmission, Installing, Jetta My 2011

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Note Always replace the needle bearing -arrow- after separating the ♦ engine and transmission. If the needle bearing in the crankshaft is damaged, the gears ♦...
  • Page 188 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – The bracket is located on the front of a removed transmission in some cases. Reattach this bracket to the »new« transmis‐...
  • Page 189 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – If not already done, replace the needle bearing in the crank‐ shaft -arrow-. Refer to ⇒ Rep. Gr. 13 ; Crankshaft; Needle Bearing in Crankshaft, Replacing .
  • Page 190 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Install the left subframe mount as follows: – Replace all bolts -1 and 2- for the left subframe mount.
  • Page 191 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Pay special attention to both vent caps -arrows- when instal‐ ling the starter. – Always adjust selector lever cable. Refer to ⇒...

  • Page 192: Tightening Specifications

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Install the bolts -arrows- for the left and right lock carrier re‐ taining brackets to the tightening specification. Refer to ⇒...
  • Page 193 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 M12 - Bolt ❑ 80 Nm ❑ When using the Insert Tool - 18 mm - T10179- : 65 Nm.
  • Page 194 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 5.4.2 1.6L/77 kW TDI Common Rail Engine Note ♦ The -arrows- point to the alignment sleeves in the engine.

  • Page 195: Transmission, Transporting And Securing To Assembly Stand

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Transmission, Transporting and Se‐ curing To Assembly Stand Special tools and workshop equipment required ♦ Holding Plate - VW309A- ♦...
  • Page 196 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Seal the Transmission So That No Fluid Can Leak Out. Caution Risk of damaging the transmission.
  • Page 197 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Lift the Transmission into the Assembly Stand. Requirement: • The transmission is sealed so that no fluid can leak out. Refer ⇒...

  • Page 198: Special Tools

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Special Tools Special tools and workshop equipment required ♦ Transmission Support - 3282- ♦ Transmission Support - Pins 29 - 3282/29- ♦...
  • Page 199 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Special tools and workshop equipment required ♦ Engine Support Bridge - 10-222A- ♦ Transmission Support - 3282- ♦...
  • Page 200 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Special tools and workshop equipment required ♦ Holding Plate - VW309A- ♦ Transmission Support - VW353- ♦...
  • Page 201 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 ♦ Guide Bolt - Mechatronic - T10406- ♦ Assembly Lever - Mechatronic - T10407- ♦ Used Oil Collection and Extraction Unit - SMN372500- ♦...
  • Page 202 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 ♦ Engine and Gearbox Jack - VAS6931- ♦ Engine Bung Set - VAS6122- , or Cap - 0AM 325 120 A- ♦...
  • Page 203 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 ♦ Engine/Gearbox Support Shackle (2 pc.) - 10-222A/12- ♦ Pry Lever - 80-200- ♦ Engine and Gearbox Jack - VAS6931- ♦...

  • Page 204: Gears, Shafts

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 35 – Gears, Shafts Gears and Shafts, Disassembling and Assembling No Gear and Shaft Repairs...

  • Page 205: Parking Lock

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Parking Lock ⇒ “2.1 Parking Lock Cover, Removing and Installing”, page 201 ⇒ “2.2 Parking Lock, Removing and Installing”, page 203 Parking Lock Cover, Removing and In‐...
  • Page 206 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Note Use pliers to remove the lock washer -1-. Do not use a sharp- ♦...

  • Page 207: Parking Lock, Removing And Installing

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Parking Lock, Removing and Installing Removing • The transmission is installed. – Remove the cover from the parking lock -1-. Refer to ⇒...

  • Page 208: Special Tools

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Special Tools Special tools and workshop equipment required ♦ Pry Lever - 80-200- Rep. Gr.35 - Gears, Shafts...

  • Page 209: Final Drive, Differential

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 39 – Final Drive, Differential Seals ⇒ “1.1 Component Location Overview - Seals”, page 205 ⇒...

  • Page 210: Right Stub Shaft Seal, Replacing

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 1 - Inner Input Shaft Seal ❑ Replacing. Refer to ⇒ “3 Clutch-Side Seals, Removing and Instal‐...
  • Page 211 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Removing Note Do not remove both drive axles from the transmission at the ♦ same time. Then it would not be possible to hold the opposite front wheel in place in order to remove or install the stub shaft bolts.

  • Page 212: Left Stub Shaft Seal, Replacing

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Install the seal all the way in without tilting it. If necessary, install a new dust ring on the stub shaft using Press Piece - Trailing Arm - 2010- .
  • Page 213 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Remove the bolt in the stub shaft using the Socket And Ex‐ tended Bit - T10107A- or Long Hex Socket - VAG1669- .

  • Page 214: Right Flange Shaft Seal, Replacing

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Install the seal all the way in without tilting it. If necessary, a new dust ring can be pressed on the stub shaft using Bearing Installer - Multiple Use - 40 - 20- .
  • Page 215 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – If equipped, remove the drive axle heat shield from the engine -arrows-. – Remove right drive axle from transmission flange shaft.

  • Page 216: Left Flange Shaft Seal, Replacing

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Drive in the new seal all the way using the Seal Installer - Flange Shaft - 3305- . Do not tilt the seal.
  • Page 217 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – If equipped, remove the Left Front Level Control System Sen‐ sor - G78- from the control arm.
  • Page 218 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 – Remove flange shaft seal. Installing – Lightly oil the new gasket on the outer circumference.

  • Page 219: Special Tools

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Special Tools Special tools and workshop equipment required ♦ Used Oil Collection and Extraction Unit - SMN372500- ♦...
  • Page 220 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 ♦ Slide Hammer Set - Hook - VW771/37- ♦ Seal Installer - Flange Shaft - 3305-...

  • Page 221: Revision History

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-Speed Dual Clutch Transmission 0AM - Edition 09.2015 Revision History DRUCK NUMBER: MEX5R008521 Fac‐ Edit Notes Quality tory Edi‐ Type Checke Edi‐ tion...
  • Page 222 All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
  • Page 223 All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
  • Page 224 All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

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