Volkswagen Golf 2013 Workshop Manual
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Volkswagen Golf 2013 Workshop Manual

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Service
Workshop Manual
Golf 2013 ➤
7-speed dual clutch gearbox 0CW
Edition 10.2012
Service Department. Technical Information

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Summary of Contents for Volkswagen Golf 2013

  • Page 1 Service Workshop Manual Golf 2013 ➤ 7-speed dual clutch gearbox 0CW Edition 10.2012 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 © 2012 Volkswagen AG, Wolfsburg D4B802791F6...

  • Page 3: Table Of Contents

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Contents 00 - Technical data ........... .
  • Page 4 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Installing to engine and gearbox support ........

  • Page 5: Technical Data

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 00 – Technical data Identification (VRL004860; Edition 10.2012) ⇒ “1.1 Gearbox identification”, page 1 Gearbox identification The following information is indicated on the gearbox (example): ♦ KHN = Gearbox code ♦...
  • Page 6 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Note The gearbox code also appears on the vehicle data stickers. Rep. gr.00 - Technical data...

  • Page 7: Technical Data

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Technical data ⇒ “2.1 Allocation gearbox - engine”, page 3 ⇒ “2.2 Capacities”, page 4 Allocation gearbox - engine Take account of the gearbox code if spare parts are required for a repair.

  • Page 8: Capacities

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Capacities The 7-speed dual clutch gearbox has two separate and different oil systems. One for the gear oil section -arrow A- and one for the hydraulic fluid section -arrow B-.

  • Page 9: Overview - Power Transmission

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Overview - power transmission ⇒ “3.1 Overview - power transmission - front-wheel drive”, page 5 Overview - power transmission - front-wheel drive The 7-speed dual clutch gearbox 0CW equipped with 5 shafts. 2 input shafts and 3 output shafts.

  • Page 10: Safety Instructions

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Safety instructions ⇒ “4.1 General safety regulations”, page 6 ⇒ “4.2 Safety precautions when working on vehicles with a Start/ Stop system”, page 6 ⇒ “4.3 Safety precautions when using test and measuring equip‐...

  • Page 11: Safety Precautions When Using Test And Measuring Equipment During A Road Test

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Safety precautions when using test and measuring equipment during a road test Observe the following if test and measuring equipment is required during a road test: WARNING Accident hazard as a result of distraction and inadequate se‐...

  • Page 12: Repair Instructions

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Repair instructions ⇒ “5.1 General notes”, page 8 ⇒ “5.2 General repair notes”, page 9 ⇒ “5.3 Gaskets, seals”, page 10 ⇒ “5.4 Nuts and bolts”, page 10 General notes Gearbox ♦...

  • Page 13: General Repair Notes

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 The gearbox has an opening in the housing. – Ensure that no small parts fall into this opening during repairs -arrow-. Cover the opening if necessary. Gearbox oil The 7-speed dual clutch gearbox has two separate and different oil systems.

  • Page 14: Gaskets, Seals

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Gaskets, seals ♦ Renew O-rings, seals and gaskets. ♦ After removing gaskets and seals, always inspect contact sur‐ face of housing or shaft for burrs resulting from removal or for other signs of damage.

  • Page 15: Clutch

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 30 – Clutch Clutch ⇒ “1.1 Assembly overview - dual clutch”, page 11 ⇒ “1.2 Removing dual clutch”, page 12 ⇒ “1.3 Installing dual clutch”, page 16 ⇒ “1.4 Renewing input shaft seal”, page 20 ⇒...

  • Page 16: Removing Dual Clutch

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 13 - Bolts ❑ Always renew after removing. ❑ 8 Nm +90° 14 - Lower section of bushing ❑ Small small engaging lever “K 2” ❑ Is removed and installed together with small engaging lever and upper section of bushing 15 - Oil seal for inner input shaft ❑...
  • Page 17 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Removing Prerequisites: • Gearbox removed and secured to engine and gearbox jack ⇒ page 90 • Mechatronic unit for dual clutch gearbox -J743- built into gear‐ box. Caution Risk of damage to gearbox.
  • Page 18 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Turn gearbox on engine and gearbox jack upwards together with clutch. Note The clutch is pulled off upwards. The mechatronic unit remains on the gearbox. – Remove retaining ring -arrow- for hub.
  • Page 19 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Position support bracket -T10323- parallel to gearbox flange as shown in illustration. – If necessary, balance out gaps using -T10356/5- , for example. – Screw in bolts -A- hand-tight.

  • Page 20: Installing Dual Clutch

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Installing dual clutch Special tools and workshop equipment required ♦ Support device -T10323- ♦ -T10356/5- from assembly tool -T10356- ♦ Puller -T10373- ♦ Thrust piece -T10376- Rep. gr.30 - Clutch...
  • Page 21 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Installing Caution Risk of damage to clutch and other components! • The positions of the engagement bearings must be set correctly. Adjustment can only be carried out before the clutch is instal‐...
  • Page 22 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Position support bracket -T10323- parallel to gearbox flange as shown in illustration. – If necessary, balance out gaps using -T10356/5- from assem‐ bly tool -T10356- , for example.
  • Page 23 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Note By pressing on, the clutch sits at the bottom against the limit ♦ stop on the input shaft. This is not the optimum position. Clutch should only be pulled up far enough for it to contact ♦...

  • Page 24: Renewing Input Shaft Seal

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Turn clutch by hand. It should be possible to turn it without difficulty. Note If the clutch is difficult to turn or if the clutch lining is being ♦...
  • Page 25 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 ♦ Tube -VW 415 A- ♦ Extractor tool -T20143/2- Requirement: • Dual clutch removed ⇒ page 12 • Clutch engagement mechanism removed ⇒ page 26 Caution Risk of damage to clutch and other components! •...

  • Page 26: Renewing Oil Seal For Inner Input Shaft

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Lever out outer oil seal. Caution The clutch can be damaged. ♦ Only drive in oil seal until it is flush, in order to avoid closing off oil drilling located behind it. Otherwise, bearing can no longer be supplied with enough oil.
  • Page 27 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 ♦ Thrust piece -T10421- Requirement: • Dual clutch removed ⇒ page 12 • Clutch engagement mechanism removed ⇒ page 26 Caution Risk of damage to clutch and other components! •...
  • Page 28 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Now screw in spindle. – Pull out oil seal using spindle. – Drive in new oil seal using thrust piece -T10421- (drive in until thrust piece contacts stop).

  • Page 29: Clutch Operation

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Clutch operation ⇒ “2.1 Assembly overview - clutch engagement”, page 25 ⇒ “2.2 Removing and installing clutch engagement”, page 26 ⇒ “2.3 Adjusting clutch engagement”, page 29 Assembly overview - clutch engagement 1 - Shim for “K 1”...

  • Page 30: Removing And Installing Clutch Engagement

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Removing and installing clutch engage‐ ment Removing • Dual clutch removed ⇒ page 12 – Remove large engaging lever with small engagement bearing. Note The upper section of guide sleeve cannot be removed or installed alone.
  • Page 31 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Note Only replace the ball pin -2- when it is worn ⇒ page 30 WARNING The hinge mounting -1- cannot be removed. Installing Install in reverse order of removal, observing the following: WARNING The position of the engagement bearings “K 1”...
  • Page 32 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 The new engaging lever »K2« with upper and lower section of guide sleeve will be delivered in transport position -illustration- and must be set to installation position prior to installation.

  • Page 33: Adjusting Clutch Engagement

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Install »small« engagement lever together with upper and low‐ er section of bushing. Insert and tighten new bolts. Specified torques ⇒ Item 9 (page 25) – Insert »large« engaging lever with measured shims for “K 1”...
  • Page 34 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 ♦ Gauge block -T10466- ♦ Ruler -T40100- Conditions • Dual clutch removed ⇒ page 12 • The gearbox flange must be level to assure good contact with the ruler.
  • Page 35 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Push in »new« ball pin by hand, if necessary using a plastic hammer and drift to tap it in. Note To avoid damage to ball pin, only tap the drift lightly with the plastic head hammer.
  • Page 36 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Fit digital 300 mm depth gauge -VAS 6594- on top of ruler - T40100- . Position depth gauge rod on outer input shaft. – Set depth gauge to “0”.
  • Page 37 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Remove retaining ring -arrow- of outer input shaft and dispose. Note It is not permissible to reuse the retaining ring. 2nd step: Determine dimension “A1” for clutch engaging lever “K 1”...
  • Page 38 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Fit digital 300 mm depth gauge -VAS 6594- on top of ruler. Position depth gauge rod on outer input shaft. • Ruler -T40100- is lying upwards across end of shaft on gear‐...
  • Page 39 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 4th step: Calculate clutch tolerance “K 1”. – Read clutch tolerance value from new clutch. • Example: Read off clutch tolerance value on clutch “K 1 = +0.2”, as shown in diagram.
  • Page 40 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Remove end gauge -T10466- and large engagement lever again. 6th step: Determine dimension “A 2” for clutch engagement bear‐ ing “K 2” Note The upper section of bushing cannot be removed or installed alone.
  • Page 41 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Hold upper section of guide sleeve with one hand. With the other hand turn the lower section of guide sleeve in direction of arrow until the sleeve moves freely.
  • Page 42 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Insert »small« engagement bearing without shim. Caution Risk of false measurements. ♦ Do not insert any shim! • Small engagement bearing only fits in one position due to 8 grooves.
  • Page 43 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Position depth gauge rod on end gauge -T10466- , as show in diagram. – In this position, determine dimension “A 2 a ” to end gauge - T10466- .
  • Page 44 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 8th step: Calculate clutch tolerance “K 2”. – Read clutch tolerance value from new clutch. • Example: Read off clutch tolerance value on clutch “K 2 = – 0.2”, as shown in illustration.

  • Page 45: Controls, Housing

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 34 – Controls, housing Mechatronic unit ⇒ “1.1 Exploded view - mechatronic unit”, page 41 ⇒ “1.2 Removing and installing mechatronic unit for dual clutch gearbox J743 ”, page 42 ⇒...

  • Page 46: Removing And Installing Mechatronic Unit For Dual Clutch Gearbox J743

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Mechatronic unit for dual clutch gearbox -J743- - specified torque and tightening sequence Note Always renew after removing. – Tighten bolts in 4 stages as follows: Stage Bolts Specified torque Screw in to contact by hand.
  • Page 47 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 ♦ Assembly lever -T10407- ♦ Guide pin -T10406- Requirement: • Gearbox is installed. Safety note on mechatronic unit for dual clutch gearbox -J743- 1. Mechatronic unit...
  • Page 48 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 DANGER! Do not work on pressure accumulator. The accumulator is un‐ der pressure and is not allowed to be opened. Caution Danger of irreparable damage to gearbox. ♦ Do not run engine or tow vehicle with mechatronic unit for dual clutch gearbox -J743- removed or when there is no gear oil in the gearbox.
  • Page 49 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Note Observe ⇒ “5 Repair instructions”, page 8 ♦ The clutch is self-adjusting. Shocks can have an effect on this ♦ adjusting device. Even if the mechatronic unit has been re‐...
  • Page 50 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Disconnect connector -1- for mechatronic unit for dual clutch gearbox -J743- . To do this, pull locking mechanism upwards -arrow-. – Unscrew nuts -2- and -3- and remove wiring retainer from gearbox.
  • Page 51 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – If fitted, remove cover on engaging levers. The cover prevents dirt getting in. – Carefully pull gearbox input speed sender 3 -G641- out of gearbox -arrow-. Note The following work step serves to lift off both engaging levers of the dual clutch from the plungers of the mechatronic unit.
  • Page 52 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Insert assembly lever -T10407- just enough until groove is flush with housing rib -arrows-, as shown in diagram. Do not insert onto stop. Note The back of the assembly lever must rest against the gearbox housing when doing this.
  • Page 53 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Note The assembly lever -T10407- must remain inserted between clutch lever and gearbox housing after removing the mechatron‐ ics. Removing the lever could have a negative effect on the clutch adjustment.
  • Page 54 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Remove bolts -B- in diagonal sequence. – Unscrew bolts -A-. – Push gearbox slightly towards rear and remove mechatronic unit from gearbox. – Make sure no oil runs out of breather.
  • Page 55 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 N - Neutral position R - Reverse gear 1 - First gear 2 - Second gear 3 - Third gear 4 - Fourth gear 5 - Fifth gear 6 - Sixth gear 7 - Seventh gear –...
  • Page 56 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Caution Risk of damaging mechatronic unit for dual clutch gearbox - J743- . When levering out the plungers, do not use the sensors as an anchor point. – Move the 4 gear actuators of the mechatronic unit for dual clutch gearbox -J743- to the specified position.
  • Page 57 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Clean sealing surface of mechatronic unit. • The seal around mechatronic unit for dual clutch gearbox - J743- must be fully and properly inserted in the groove. – Put on mechatronic unit.
  • Page 58 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Pull sealing plug off breather connection on mechatronic unit and fit breather cap -arrow-. Note The breather cap on the mechatronic unit is destroyed during ♦ removal and must be renewed.

  • Page 59: Moving Mechatronic Unit For Dual Clutch Gearbox J743 Into Removal Position By Hand

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Moving mechatronic unit for dual clutch gearbox -J743- into removal posi‐ tion by hand Note Only if you cannot set the mechatronic unit to removal position with the vehicle diagnostic tester , you must move the unit by hand to this position.
  • Page 60 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Remove cover for parking lock -1- ⇒ page 180 Caution Risk of causing permanent damage by mechatronic unit falling out. ♦ After the next work step, the mechatronic unit is free and could fall out.

  • Page 61: Selector Mechanism

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Selector mechanism ⇒ “2.1 Assembly overview - selector mechanism”, page 57 ⇒ “2.2 Emergency release from position P”, page 58 ⇒ “2.3 Removing and installing selector lever handle”, page 59 ⇒...

  • Page 62: Emergency Release From Position P

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 ❑ 13 Nm 9 - Bolt ❑ Qty. 3 ❑ 8 Nm 10 - Cable support bracket ❑ For selector lever cable 11 - Gearbox selector lever 12 - Bolt ❑...

  • Page 63: Removing And Installing Selector Lever Handle

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Removing and installing selector lever handle Brief description Handle is removed together with selector cover. Removing – Shift selector lever to position “D”. The push button -arrow- does not need to be pulled out by hand.

  • Page 64: Moving Push Button To Installation Position In The Handle

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Note It is possible for the push button in the handle to be pressed. ♦ Never install a handle with the push button pressed in. ♦ Move push button to installation position ⇒...
  • Page 65 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 There are 2 ways of moving the push button into the installation position, »with« and »without« installation guard. Both of them are described here. Place handle »with« installation guard in installation position: When using the installation guard, make sure that it has an eyelet -arrow- at the front.

  • Page 66: Removing And Installing Selector Mechanism

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Using a screwdriver, for example, press small lever -1- for pull rod into groove -2-. When doing this, button -3- is pushed back into installation position. -I- Push button in pressed position...
  • Page 67 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Remove securing clip. Use pliers to remove the securing clip on the cable support brack‐ et. Do not use a sharp-edged lever. The selector lever cable could otherwise be damaged.
  • Page 68 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 2.5.2 Removing and installing selector mech‐ anism without selector lever cable Brief description In the interior the centre console is to be removed. The heat shield beneath the vehicle must be removed.
  • Page 69 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Remove nuts -arrows- inside vehicle. – If fitted, remove bracket -A-. – Remove selector mechanism -B- together with selector hous‐ ing downwards. Installing Install in reverse order of removal. During this step, observe the...

  • Page 70: Removing And Installing Selector Lever Cable

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Install new securing clip -arrow- and insert plug. – Install heat shield below selector mechanism ⇒ General body repairs, exterior; Rep. gr. 66 ; Mouldings/trims/extensions; Assembly overview - heat shield .
  • Page 71 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Remove plug and securing clip -arrow-. Always renew securing clip. – Fit a large screwdriver in grooves of locking mechanism and turn it 90° in direction of arrow.

  • Page 72: Checking Selector Mechanism

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – The selector lever cable is properly engaged when the grooves in the locking mechanism are at right angles to the selector lever cable. – Install new securing clip -arrow- and insert plug.

  • Page 73: Checking And Adjusting Selector Lever Cable

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Selector lever is locked and cannot be shifted out of “P” position when the button is pressed. Solenoid for selector lever lock blocks selector lever. • Brake pedal is depressed: Solenoid for selector lever lock releases selector lever.
  • Page 74 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Checking – Move selector lever to position »P« position. – Remove cable from lever on gearbox. – Move selector lever repeatedly from »P« to »S« and back to »P«.

  • Page 75: Renewing Oil Seal For Selector Shaft

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Install Bowden cable with loosened adjusting screw -arrow- and new securing clip. WARNING The parking lock must be engaged. – To do this, turn both front wheels simultaneously »under the car«...

  • Page 76: Removing And Installing Gearbox

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Removing and installing gearbox ⇒ “3.1 Removing gearbox”, page 72 ⇒ “3.2 Installing gearbox”, page 86 ⇒ “3.3 Specified torques for gearbox”, page 89 Removing gearbox ⇒ “3.1.1 Removing gearbox, vehicles with gasoline engine”, page ⇒...
  • Page 77 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Special tools and workshop equipment required ♦ Support bracket -10-222A- ♦ Shackle -10 - 222 A /12- ♦ Support bracket -10 - 222 A /31- ♦ Engine support basic set - T40091- ♦...
  • Page 78 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 ♦ Shock absorber set -T10001- ♦ Tensioning strap -T10038- ♦ Engine support supplement set -T40093/3-5- ♦ Not illustrated: Engine and gearbox jack -V.A.G 1383 A- Removing – Raise vehicle. All 4 supports of lifting platform must be at same height.
  • Page 79 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Lever selector lever cable -1- off gearbox selector lever. – Remove bolts -2- and tie up selector lever cable together with support bracket. Caution Risk of damage to selector lever cable.
  • Page 80 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Unscrew upper engine/gearbox connecting bolt with a suitable socket from shock absorber set -T10001- . – Remove filler pipe for washer fluid reservoir of windscreen washer system ⇒ Electrical system; Rep. gr. 92 ; Windscreen washer system;...
  • Page 81 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Remove filler pipe for washer fluid reservoir of windscreen washer system ⇒ Electrical system; Rep. gr. 92 ; Windscreen washer system; Removing and installing washer fluid reser‐ voir .
  • Page 82 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Lower engine/gearbox assembly using spindle -10 - 222 A / 11- until distance -a- is obtained between gearbox housing and gearbox mounting. • Dimension -a- = 50 mm –...
  • Page 83 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Renew needle bearing in crankshaft ⇒ Rep. gr. 13 ; Crank‐ shaft; Renewing needle bearing in crankshaft . Transporting gearbox ⇒ page 90 Secure gearbox to assembly stand ⇒...
  • Page 84 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Special tools and workshop equipment required ♦ Support bracket -10-222A- ♦ Shackle -10 - 222 A /12- ♦ Support bracket -10 - 222 A /31- ♦ Engine support basic set - T40091- ♦...
  • Page 85 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 ♦ Tensioning strap -T10038- ♦ Insert tool, 18 mm -T10179- ♦ Adapter -T40093/3-6- ♦ Not illustrated: Engine and gearbox jack -V.A.G 1383 A- Removing – Raise vehicle. All 4 supports of lifting platform must be at same height.
  • Page 86 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Lever selector lever cable -1- off gearbox selector lever. – Remove bolts -2- and tie up selector lever cable together with support bracket. Caution Risk of damage to selector lever cable.
  • Page 87 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Disconnect connector -1- from oil level and oil temperature sender -G266- . – Remove subframe without steering box ⇒ Running gear, axles, steering; Rep. gr. 40 ; Subframe; Removing and instal‐...
  • Page 88 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Slide connector -T40091/3- onto support bracket -10-222 A- . – Bolt engine support bracket -10-222 A- to adapter -10 - 222 A /31-1- and adapter -10 - 222 A /31-2- .
  • Page 89 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Lower engine/gearbox assembly using spindle -10 - 222 A / 11- until distance -a- is obtained between gearbox housing and gearbox mounting. • Dimension -a- = 50 mm –...

  • Page 90: Installing Gearbox

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Renew needle bearing in crankshaft ⇒ Rep. gr. 13 ; Crank‐ shaft; Renewing needle bearing in crankshaft . Transporting gearbox ⇒ page 90 Secure gearbox to assembly stand ⇒...
  • Page 91 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Check that there are dowel sleeves -A- for centring engine and gearbox fitted in the cylinder block. Insert any missing dowel sleeves. – Check condition of needle bearing -arrow- in crankshaft; re‐...
  • Page 92 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Bolt cable support bracket -1- to gearbox. Install left assembly mounting as follows: – Renew all bolts on left assembly mounting. – First screw in all bolts by hand.

  • Page 93: Specified Torques For Gearbox

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Specified torques for gearbox Gearbox to engine: Item Bolt 1, 3 M12x55 M12x170 4, 8 M12x65 5, 6, 7 M10x55 Dowel sleeve for centring • Also secures starter Component...

  • Page 94: Transporting Gearbox

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Transporting gearbox Special tools and workshop equipment required ♦ Workshop hoist -VAS 6100- ♦ Shackle -10 - 222 A /12- ♦ Engine bung set -VAS 6122- Rep. gr.34 - Controls, housing...
  • Page 95 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Seal gearbox so that it is oil-tight. Caution Risk of damage to gearbox. Before repairs, the breather of the mechatronic unit for dual clutch gearbox -J743- (-rear arrow-) and the gearbox breather (-front left arrow-) must be sealed so that no oil can escape.
  • Page 96 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Transporting gearbox: Requirement: • Gearbox is sealed so that no oil can escape ⇒ page 91 Rep. gr.34 - Controls, housing...

  • Page 97: Installing To Engine And Gearbox Support

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Installing to engine and gearbox support Special tools and workshop equipment required ♦ Support plate -VW 309- ♦ Gearbox support -VW 353- ♦ Shackle -10 - 222 A /12- ♦...
  • Page 98 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Lifting gearbox into engine and gearbox support Requirement: • Gearbox is sealed so that no oil can escape ⇒ page 91 The gearbox is lifted onto the engine and gearbox support -VAS 6095- together with the gearbox support -VW 353- using the workshop hoist -VAS 6100- .

  • Page 99: Dismantling And Assembling Gearbox

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Dismantling and assembling gearbox ⇒ “6.1 Schematic overview - gearbox”, page 95 ⇒ “6.2 Dismantling and assembling gearbox”, page 96 Schematic overview - gearbox A - Outer input shaft...

  • Page 100: Dismantling And Assembling Gearbox

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 For every installation on shafts, always check »lower« bearing. It is easy for bearing cages to become bent and damaged by »bumping«. Bearing races are not allowed to be swapped over. They are paired with the bearing.
  • Page 101 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Remove cable support bracket. – Remove lever and cover. – Remove parking lock ⇒ page 181 – Remove dual clutch ⇒ page 12 – Remove clutch engagement ⇒ page 26 –...
  • Page 102 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Remove connecting bolts of housing halves at clutch end. – Fit support bridge -T10323- and rotate spindle against inner input shaft until finger tight. This supports shaft. Gearbox housing is pulled off later. In this way, the force required is not applied to the gearbox in an uncon‐...
  • Page 103 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Remove retaining ring. – Remove dowel sleeves of mechatronic unit. – From above, mount another puller. Screw on -A- square pin -T10427/1- and -B- angled rod -T10427- until finger-tight.
  • Page 104 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Move selector fork for 1st and 3rd gear upwards into 1st gear. – Slightly raise output shaft 1, tip it is a little -arrow- and remove selector fork.
  • Page 105 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Raise output shafts 2 and 3 out of the lower bearings. – Place both shafts »in direction of« selector forks onto clutch housing. – Screw one guide pin -3411- into differential.
  • Page 106 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Turn selector forks »inwards«. – Remove selector forks. – Remove inner input shaft. – There is a roller bearing between inner and outer input shaft. Also remove this.
  • Page 107 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Outer input shaft can be pressed out now. – Hold shaft firmly with one hand. This prevents it from falling down. Note »Pressed out« shaft will fall down.
  • Page 108 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Warm clutch housing in area of outer input shaft to approx. 100 °C using a hot air blower. • If housing has been heated correctly then outer input shaft can be inserted by hand up to stop.
  • Page 109 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Insert inner input shaft with roller bearing. Bearing is not allowed to be broken. Oil bearing. – Shift all locking collars of output shafts 2 and 3 »downwards«.
  • Page 110 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 For the following steps: Tapered roller bearings are destroyed very quickly if the cage is bent due to being inserted forcefully or knocked. – Insert output shaft 2. – Watch out for both locking collars. Mouth »top« and mouth »bottom«...
  • Page 111 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – On output shaft 1, shift »upper« locking collar upwards. – Insert output shaft 1 »at an angle from above«. Shaft should remain at an angle. This is because selector forks must still be installed before shaft is set in installation position.
  • Page 112 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Raise inner input shaft slightly. In this way, you can move out‐ put shaft 1 into its installation position. – After insertion, position all selector forks in neutral position.
  • Page 113 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Shaft should only be supported. It is only allowed to be pushed up until gear for 7th gear on inner input shaft -A- touches syn‐ chromeshed gear for 3rd gear on output shaft 1 -B-.
  • Page 114 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Make sure retaining ring is fitted correctly. Ring is »narrower at top«. Its installation position is as well. The retaining ring pliers also engage better like this. – Install new retaining ring.
  • Page 115 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – To do this: engage 1st gear. – Use hub of clutch for turning. This prevents tapered roller bearings from being damaged whilst being »seated in bearing seat«. – Tighten new connecting bolts.
  • Page 116 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Install drain plug. – Install oil seals of input shafts ⇒ page 20 If large oil seal has already been renewed, it does not need to be renewed again.
  • Page 117 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Install lever and cover. – Fit cable support bracket. Specified torques: 8 Nm – Use your hand to press lever to stop in direction of cable sup‐ port bracket.

  • Page 118: Gearbox Housing, Clutch Housing

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Gearbox housing, clutch housing ⇒ “7.1 Repairing gearbox housing”, page 114 ⇒ “7.2 Repairing clutch housing”, page 117 Repairing gearbox housing 1 - Gearbox housing ❑ With oil guide ⇒...
  • Page 119 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Pressing in bearing for inner input shaft – Press in bearing bearing to stop. – Install »new« retaining ring. Installation position of oil guide in gearbox housing – Oil guide is clipped into housing.
  • Page 120 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Preparing bearing races of output shafts 2 and 3 for pressing in – First insert one shim into housing. – Then position »correct« bearing race and drive bearing race in using targeted, light taps until it can no longer drop out.

  • Page 121: Repairing Clutch Housing

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Driving in differential bearing race A second mechanic is required for driving in. – Place thrust piece -T10380- on edge of workbench. Position gearbox housing with area of bearing point on thrust piece, and hold housing firmly like that.
  • Page 122 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 11 - Outer input shaft ❑ Removing ⇒ page 96 ❑ Installing ⇒ page 103 ❑ Dismantling and assembling ⇒ page 123 12 - Centring sleeve ❑ Qty. 2 Preparing output shaft bearing race 2 for pressing in –...
  • Page 123 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Driving out differential bearing race – Drive out bearing using a suitable drift. Oil scraper ring is destroyed during removal and must be re‐ newed. Pressing in differential bearing race Pulling out output shaft bearing race 1 There is 1 shim under bearing.
  • Page 124 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Preparing output shaft bearing race 1 for pressing in – First place tube -VW 415 A- under bearing seat. This illustration show view »from below«. This means press pres‐...

  • Page 125: Gear Oil

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Gear oil ⇒ “8.1 Draining and filling gear oil”, page 121 Draining and filling gear oil Special tools and workshop equipment required ♦ Used oil collection and extraction unit -V.A.G 1782- ♦...
  • Page 126 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 The new oil is poured in through the breather hole. Vehicles with diesel engine: Remove air filter housing ⇒ Rep. gr. 23 ; Air filter; Removing and installing air filter housing .

  • Page 127: Gears, Shafts

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 35 – Gears, shafts Input shaft ⇒ “1.1 Dismantling and assembling input shaft”, page 123 Dismantling and assembling input shaft ⇒ “1.1.1 Dismantling and assembling outer input shaft”, page 123 ⇒...
  • Page 128 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Installing retaining ring Objective is to secure bearing with retaining ring without play. To achieve this, select ring that fits into groove without play. – Press ring all-around into groove.
  • Page 129 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Pressing off gear wheel for 7th gear Pressing on gear wheel for 7th gear – Carefully press on to stop. Pressing off gear wheel for 3rd gear Pressing on gear wheel for 3rd gear –...
  • Page 130 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Pressing off gear wheel for 5th gear Pressing on gear wheel for 5th gear – Heat to 140 °C to press on. – Carefully press on to stop. – Align tube -2040- on thrust plate -VW 401- so that shaft can be pushed through downwards without »bumping«.

  • Page 131: Output Shaft

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Output shaft ⇒ “2.1 Assembly overview - output shaft”, page 127 ⇒ “2.2 Dismantling and assembling output shaft 1”, page 131 ⇒ “2.3 Dismantling and assembling output shaft 2”, page 139 ⇒...
  • Page 132 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 22 - Synchro-ring 23 - Outer ring 24 - Synchro-ring 25 - Needle bearing 26 - Sleeve for needle bearing 27 - Synchromeshed gear for 1st gear 28 - Thrust washer...
  • Page 133 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 2.1.2 Assembly overview - output shaft 2 1 - Output shaft 2 2 - Needle thrust bearing 3 - Needle bearing 4 - Reverse gear wheel 5 - Washer...
  • Page 134 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 • Bearing races are not allowed to be swapped over. They are paired with the bearing. 25 - Bearing ❑ Pressing off ⇒ page 139 ❑ Pressing on ⇒ page 140 Note 2.1.3...

  • Page 135: Dismantling And Assembling Output Shaft 1

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Dismantling and assembling output shaft 1 ⇒ “2.2.1 Dismantling output shaft 1 partially”, page 131 ⇒ “2.2.2 Dismantling output shaft 1 completely”, page 132 ⇒ “2.2.3 Assembling output shaft 1”, page 133 ⇒...
  • Page 136 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 2.2.2 Dismantling output shaft 1 completely Press off bearing of output shaft 1. – First destroy cage of bearing. – Press off bearing inner race. Note Shaft will fall out downwards! Therefore, position suitable items under press.
  • Page 137 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Remove bolt. Special wrench -T10035- can also be used. – Press out output shaft completely. Note Shaft will fall out downwards! Therefore, position suitable items under press. It is also possible to hold shaft by hand.
  • Page 138 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 • If bearing is pressed on, thrust plate -VW 447 i- must also be used for each pressing operation. • Pressing off bearing: ⇒ page 132 • Pressing on bearing: ⇒...
  • Page 139 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Press on synchro-hub. Note Bear two things in mind when pressing: ♦ Raise gear wheel and turn it at same time. This allows syn‐ ♦ chro-ring to locate its installation position before ring is clam‐...
  • Page 140 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Put on synchromeshed gear for 4th gear. – Press on washer. Note Here also stop pressing immediately when you notice a rise in ♦ force during pressing. Do not re-press! ♦...
  • Page 141 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Fit needle bearing. – Wet bearing and friction surfaces with oil. – Put on synchromeshed gear for 3rd gear, small synchro-ring, outer ring and large synchro-ring. – Press on locking collar and synchro-hub.
  • Page 142 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Fit needle bearing. – Wet bearing and friction surfaces with oil. – First place small synchro-ring onto synchromeshed gear for 1st gear. – Then outer ring and then large synchro-ring.

  • Page 143: Dismantling And Assembling Output Shaft 2

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 2.2.4 Dismantling and assembling locking col‐ lars and synchro-hubs of output shaft 1 Dismantling and assembling 2nd and 4th gear locking collar and synchro-hub Lettered side of synchro-hub faces groove in locking collar.
  • Page 144 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Press on bearing of output shaft 2. – Remove bolt. Special wrench -T10035- can also be used. – Press out output shaft completely. Note Shaft will fall out downwards! Therefore, position suitable items under press.
  • Page 145 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Place both needle bearings onto output shaft. – Make sure that cages are not broken. – Wet bearing with oil. – Fit reverse gear wheel. – Put on reverse gear wheel, axial bearing »with smooth side facing upwards«.
  • Page 146 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Put on synchro-ring, needle bearing and synchromeshed gear for 6th gear. – Wet bearing and friction surfaces with oil. – Press on washer for synchromeshed gear for 6th gear.
  • Page 147 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Put on needle bearing, synchromeshed gear for 7th gear and synchro-ring. – Wet bearing and friction surface with oil. – Put on locking collar with synchro-hub. Make sure circumfer‐...
  • Page 148 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Put on synchro-ring, needle bearing and gear wheel for 5th gear. – Wet bearing and friction surface with oil. – Press on bearing. – Wet bearing with oil.

  • Page 149: Dismantling And Assembling Output Shaft 3

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Locking collar and synchro-hub for synchromeshed gear for 7th and 5th gears Dismantling and assembling output shaft 3 ⇒ “2.4.1 Dismantling output shaft 3”, page 145 ⇒ “2.4.2 Assembling output shaft 3”, page 147 ⇒...
  • Page 150 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Press on bearing of output shaft 3. – Press off parking lock gear together with bearing. Note Shaft will fall out downwards! Therefore, position suitable items under press. It is also possible to hold shaft by hand.
  • Page 151 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 2.4.2 Assembling output shaft 3 In this procedure, you will see how output shaft 3 is assembled. Make sure that shaft bearing is not damaged during following work on press.
  • Page 152 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Press on synchro-hub and locking collar. – Fit retaining ring. – Insert -stop ring-. – Put on parking lock gear and bearing. – Press on both together. 2.4.3 Dismantling and assembling locking col‐...

  • Page 153: Determining Shims

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Determining shims ⇒ “2.5.1 Notes on gearbox adjustment”, page 149 ⇒ “2.5.2 Calculating shims for clutch housing”, page 150 ⇒ “2.5.3 Calculating shims for gearbox housing”, page 161 2.5.1 Notes on gearbox adjustment Adjustment work is divided into 2 »sections«:...
  • Page 154 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 • Follow this procedure step by step. Temperature differences, such as »summer and winter«, affect all measuring tools that are used. • Numbers given in the calculations below are in millimetres.
  • Page 155 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Note Do not install any oil deflectors or shims when calculating which shims to use. Only install bearing races of shafts. • Outer input shaft is installed ⇒ page 117 •...
  • Page 156 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Assemble measuring tool -T10425- for work on clutch housing. Specified torque: 15 Nm – Place measuring tool -T10425- on dowel sleeves. – Place drift -T10425/3- on output shaft 1.
  • Page 157 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Fit depth gauge -VAS 6619- on outer input shaft. Shown here in »green«. Set depth gauge to »zero«. – Use depth gauge -VAS 6619- to measure on 4th gear wheel of output shaft 1.
  • Page 158 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Gear wheel for 4th gear has axial play on shaft. This play is not allowed to »influence« size of subsequent shim. Therefore, axial play is measured. – Call this value “B”.
  • Page 159 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Place drift -T10425/3- on output shaft 2. Turn mark on outer input shaft »into alignment« with output shaft Note Gears of shafts have helical gearing. It is possible for shafts to be raised out of their bearing when they are turned.
  • Page 160 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Three measurements are taken. Use »existing« mark for orientation. – Turn input shaft by 120° further and repeat measurement. Then turn through another 120° and measure again. Note Gears of shafts have helical gearing.
  • Page 161 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 This play is not allowed to »influence« size of subsequent shim. Therefore, axial play is measured. – Call this value “B”. – Note reading. – Calculation: “A” minus “B” = calculated shim thickness.
  • Page 162 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – First measure thickness of synchromeshed gear for reverse gear. – Make a note of this value and call it “B”. Adjust output shaft 3. Output shaft 3 is set correctly when dimension -K- = 19.9 milli‐...
  • Page 163 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Zero depth gauge -VAS 6594- on synchromeshed gear for re‐ verse gear. – Measure distance from housing flange surface. – Make sure that burrs on teeth are not included in measure‐...
  • Page 164 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Top edge of gear wheel to housing flange surface “A” minus thickness of gear wheel “B” = actual value for “K”. Output shaft 3 is set correctly when dimension -K- = 19.9 milli‐...
  • Page 165 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 2.5.3 Calculating shims for gearbox housing Brief description This »section« explains how to calculate thickness of shims in gearbox housing. 4 shims are installed in total. There is 1 shim on each output shaft.
  • Page 166 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 The correct shim can then be calculated in each case. • Do not insert differential yet. Output shafts 1, 2 and 3 are in their bearings. Adhere to following work procedures: –...
  • Page 167 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Put on bearing race, drift and headpiece. – Tap drift »lightly« with a plastic hammer. – Rotate outer input shaft whilst tapping. This locates output shaft 1 correctly in its bearing seat.
  • Page 168 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Measure distance (height) from drift to measuring tool - T10425- . – Call this value “b”. – Note reading. Example: “b” = 163.85 mm Height of output shaft 1 = “a” plus “b” minus height of drift “D” = 264.97 mm + 163.85 mm - 230.03 mm = 198.79 mm...
  • Page 169 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Always measure close to the respective bearing position. – Call this value “a2”. – Note reading. Example: “a2” = 264.93 mm – Measure distance (height) from drift to measuring tool - T10425- .
  • Page 170 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Zero depth gauge -VAS 6594- on measuring tool -T10425- . – Measure distance (height) from surface of measuring tool - T10425- to flange surface of clutch housing. Always measure close to the respective bearing position.
  • Page 171 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Measure distance (height) from drift to measuring tool - T10425- . – Call this value “b3”. – Note reading. Example: “b3” = 85.59 mm Height of output shaft 3 = “a3” plus “b3” minus height of drift “D”...
  • Page 172 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Measure height of drift -T10425/3- with adapter -T10425/4- . Note length (height) of drift. Its height is needed in subsequent calculations. Height of drift D=? mm. Example: D = 256.00 mm Note Each drift responds to ambient temperature.
  • Page 173 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Measure distance (height) from surface of measuring tool - T10425- to flange surface of clutch housing. Measure at 2 more points to keep inaccuracies as low as possible.
  • Page 174 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Secure gearbox housing in a vice using support bridge - T10323- . – Insert dowel sleeves in gearbox housing. – Set measuring tool on gearbox housing. – Place measuring tool -T10425- on dowel sleeves.
  • Page 175 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Measure at seat of bearing race in gearbox housing. – Note calculated result for “depth of output shaft 1”. Example: “depth for output shaft 1” = 199.89 mm Now value for “height of output shaft 1”...
  • Page 176 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – From the supplied shims, measure and select the one that is required. WARNING Later on, only insert this 1 shim. Not 2. Continue with measurements for output shaft 2: Bearing preload for this output shaft 2 is: 0.30 mm.
  • Page 177 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Measure at seat of bearing race in gearbox housing. – Note calculated result for “depth of output shaft 2”. Example: “depth for output shaft 2” = 175.18 mm Now value for “height of output shaft 2”...
  • Page 178 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – From the supplied shims, measure and select the one that is required. WARNING Later on, only insert this 1 shim. Not 2. Continue with measurements for output shaft 3: Bearing preload for this output shaft 3 is: 0.15 mm.
  • Page 179 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Measure at seat of bearing race in gearbox housing. – Note calculated result for “depth of output shaft 1”. Example: “depth for output shaft 3” = 121.40 mm Now value for “height of output shaft 3”...
  • Page 180 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Bearing preload for differential is: 0.20 mm. Remove measuring tool -T10425- . Calculate depth of differential: To measure depth of differential as accurately as possible, meas‐ ure at 3 points around bearing seat. »Average« the measurement results.
  • Page 181 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Measure 3 times around bearing seat -arrows-. Measure carefully. – Make a note of average of these 3 measurements. Example: 16.25 mm + 16.24 mm + 16.27 mm3 = 16.25 mm Example: second measurement result = 16.25 mm...
  • Page 182 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Measure 3 times around bearing seat -arrows-. Measure carefully. – Make a note of average of these 3 measurements. Example: 16.24 mm + 16.24 mm + 16.21 mm3 = 16.23 mm Example: third measurement result = 16.23 mm...
  • Page 183 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – From the supplied shims, measure and select the one that is required. WARNING Later on, only insert this 1 shim. Not 2. – Installing shims and bearing races of gearbox housing ⇒...

  • Page 184: Parking Lock

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 Parking lock ⇒ “3.1 Removing and installing cover for parking lock”, page 180 ⇒ “3.2 Removing and installing parking lock”, page 181 Removing and installing cover for park‐ ing lock Special tools and workshop equipment required ♦...

  • Page 185: Removing And Installing Parking Lock

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Unscrew bolt -3- and detach gearbox selector lever -4-. – Unscrew bolts -2- and remove parking lock cover -1-. Installing Cover for parking lock must be renewed if seal for selector shaft or seal on cover for parking lock is leaking.
  • Page 186 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Remove bolts -2- and pull parking lock -1- off dowel sleeves -arrows-. If parking lock cannot be removed by hand: – Apply multi-purpose tool -VW 771- with extractor tool -VW 771/37- behind parking lock and remove parking lock by pull‐...

  • Page 187: Final Drive - Differential

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 39 – Final drive - differential Oil seals ⇒ “1.1 Overview of fitting locations - seals”, page 183 ⇒ “1.2 Renewing left oil seal”, page 183 ⇒ “1.3 Renewing right oil seal”, page 186...
  • Page 188 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 ♦ Multipurpose tool -VW 771- ♦ Thrust piece -3305- ♦ Socket -T10107 A- ♦ Sealing grease ⇒ Electronic Parts Catalog (ETKA) Removing • Gearbox is installed. Note Observe ⇒ “5 Repair instructions”, page 8 –...
  • Page 189 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Step on the brake pedal while a 2nd mechanic loosens the left drive shaft bolt -arrow-. – Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐...

  • Page 190: Renewing Right Oil Seal

    Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Fill space between sealing lip and dust lip -arrow- with sealing grease ⇒ Electronic Parts Catalog (ETKA) . – Drive in new oil seal to stop, being careful not to cant oil seal.
  • Page 191 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 ♦ Socket -T10107 A- ♦ Tensioning strap -T10038- ♦ Sealing grease ⇒ Electronic Parts Catalog (ETKA) Removing • Gearbox is installed. Note Observe ⇒ “5 Repair instructions”, page 8 –...
  • Page 192 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Unscrew nuts -arrows- for right swivel joint. – If fitted, unscrew nut on bracket for front right vehicle level sender -G289- . – Detach right swivel joint from transverse link.
  • Page 193 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – Screw 2 bolts into flange and counterhold flange shaft with a lever in order to remove and install flange shaft. – Remove flange shaft along with spring, thrust washer and ta‐...
  • Page 194 Golf 2013 ➤ 7-speed dual clutch gearbox 0CW - Edition 10.2012 – If present, install heat shield above right drive shaft. Specified torque ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .

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