Volkswagen Golf 2015 Repair Manual
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Volkswagen Golf 2015 Repair Manual

Direct shift gearbox
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Repair Manual
Golf 2015 ➤
Golf Variant 2015 ➤
Direct Shift Gearbox
Edition 09.2015
Service Department. Technical Information

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Table of Contents
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Summary of Contents for Volkswagen Golf 2015

  • Page 1 Service Repair Manual Golf 2015 ➤ Golf Variant 2015 ➤ Direct Shift Gearbox 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 D4B804111B4...

  • Page 3: Table Of Contents

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Contents 00 - General, Technical Data ..........
  • Page 4 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Transmission, Disassembling and Assembling ........101 Overview - Transmission .

  • Page 5: General, Technical Data

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 00 – General, Technical Data Identification (Edition 09.2015) ⇒ 1.1 Transmission Identification , page 1 Transmission Identification Example -arrow-: GKF - Transmission Code 10.05.2 - 05/10/2002...
  • Page 6 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Reading the Transmission Code on the Transmission Installed To read the transmission code letters under the console directly from the transmission, the engine and transmission must be sup‐...

  • Page 7: Safety Precautions

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Safety Precautions ⇒ 2.1 General Safety Precautions , page 3 ⇒ 2.2 Start/Stop System Safety Precautions , page 3 ⇒ 2.3 Safety Precautions when Tow Starting and Towing , page ⇒...

  • Page 8: Safety Precautions When Tow Starting And Towing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Safety Precautions when Tow Starting and Towing Caution Danger of causing damage to the transmission. ♦ When towing the vehicle, the selector lever must be in N and the vehicle must not be towed further than 50 km (31 miles) and not faster than 50 km/h (31 mph).

  • Page 9: Repair Information

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Repair Information ⇒ 3.1 General Information , page 5 ⇒ 3.2 Clean Working Conditions , page 5 ⇒ 3.3 General Repair Information , page 6 ⇒ 3.4 Seals, Sealing Rings , page 7 ⇒...

  • Page 10: General Repair Information

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 ♦ Protect the disconnected connectors from dirt and moisture and only connect when they are dry. General Repair Information Carefulness, cleanliness and the correct tools are required for transmission repairs to be successful.

  • Page 11: Seals, Sealing Rings

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Fluid Drain and Check Plug A plastic overflow tube is located behind this screw -arrow- (with 8 mm hex socket head). Its length determines the oil level in the transmission.

  • Page 12: Bolts And Nuts

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Bolts and Nuts ♦ Loosen or tighten bolts and nuts on the covers or housings diagonally. ♦ The tightening specifications stated apply to non-oiled nuts and bolts.

  • Page 13: Technical Data

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Technical Data ⇒ 4.1 Transmission/Engine Allocation , page 9 ⇒ 4.2 Capacities , page 9 ⇒ 4.3 Gear Ratio Calculation , page 10 Transmission/Engine Allocation Always use refer to the transmission code letters if a repair re‐...

  • Page 14: Gear Ratio Calculation

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Gear Ratio Calculation Example: 6th Gear Final Drive Drive gear ZG 1 = 45 ZA 1 = 21 Driven gear ZG 2 = 28 ZA 2 = 70...

  • Page 15: Electrical Components

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Electrical Components Component Location Overview - Electrical Components 1 - DSG Transmission Mecha‐ tronic - J743- ❑ Installed behind the transmission cover ❑ Removing and Instal‐...

  • Page 16: Special Tools

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Special Tools Special tools and workshop equipment required ♦ Not Illustrated: ♦ Engine Support Bridge - 10-222A- Rep. Gr.00 - General, Technical Data...

  • Page 17: Clutch

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 30 – Clutch Clutch ⇒ 1.1 Overview - Dual Clutch , page 13 ⇒ 1.2 Clutch End Cover, Removing and Installing , page 15 ⇒ 1.3 DSG® Clutch, Removing , page 19 ⇒...
  • Page 18 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 1 - Dual Clutch with Circlip Caution ♦ The drive plate (upper section of the dual clutch) of a new clutch is not se‐ cured with the circlip, it only sits »taut«...

  • Page 19: Clutch End Cover, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 ® 1 - DSG Clutch/Clutch Hous‐ ❑ Outer clutch pack carri‐ 2 - Seals ❑ Quantity: 4 3 - Inner Clutch Pack Carrier ❑ Do not remove...
  • Page 20 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Note Clean the Clutch Cover Plate Guide Sleeve - T10302- before us‐ ing, and do not use any scratched sleeves Brief Description The clutch cover seals the transmission toward the outside. It is held in place by a circlip.
  • Page 21 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Lift the clutch cover -2- through the opening in the starter with a screwdriver -1- or a pry bar in direction of -arrow- and then remove it.
  • Page 22 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Clean the Clutch Cover Plate Guide Sleeve - T10302- before using, do not use any scratched sleeves – Place the sleeve on a level surface.

  • Page 23: Dsg® Clutch, Removing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Only remove bushing once circlip is installed. – Install the transmission. Refer to ⇒ 3.2 Transmission, Installing , page 91 – Fill with transmission fluid. Refer to ⇒...
  • Page 24 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Remove the circlip -2- from the drive plate with a screwdriver -1- in direction of -arrow- and dispose of it. Important! Installed Position of the Drive Plate –...

  • Page 25: Dsg® Clutch, Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Remove the circlip -arrow- and dispose of it. Note This circlip must be replaced and re-measured during installation. Caution ® Carefully remove the DSG clutch. Make sure that no other parts of the clutch fall out;...
  • Page 26 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Caution ♦ The drive plate of a new clutch is not secured with the circlip, it only sits taut in the clutch. ♦ Thus, press the drive plate into the outer clutch pack car‐...
  • Page 27 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Important! Installed Position of the Drive Plate – Verify that the protruding tab -arrow- of the drive plate is posi‐ tioned between the color-marked teeth of the outer clutch pack carrier.
  • Page 28 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Remove the drive plate from the installed clutch in the direction of -arrows-, if necessary, use a screwdriver to carefully pry it out of the teeth of the outer clutch pack carrier.
  • Page 29 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Place the gauge button -on the hub of the large clutch pack carrier-. • The tip of the dial may not be placed on the circlip.
  • Page 30 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Insert the drive plate into the DSG ® clutch. • The protruding tab of the drive plate must be positioned be‐ tween the color-marked teeth of the outer clutch pack carrier.

  • Page 31: Special Tools

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Special Tools Special tools and workshop equipment required ♦ Clutch Cover Plate Guide Sleeve - T10302- ♦ Clutch Retaining Bar - T10303- ♦ Dial Gauge - 0-10mm - VAS6079- ♦...

  • Page 32: Controls, Housing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 34 – Controls, Housing Mechatronic ⇒ 1.1 Overview - Mechatronic , page 28 ⇒ 1.2 Mechatronic, Removing and Installing , page 30 Overview - Mechatronic 1 - Transmission Fluid Drain and Check Plug ❑...
  • Page 33 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 7 - Seal ❑ Replace after removing 8 - DSG Transmission Mechatronic - J743- ❑ Replace the O-ring after disassembly. ❑ With O-rings on connector ❑ Removing and installing. Refer to ⇒...

  • Page 34: Mechatronic, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Tightening Specification and Sequence for DSG Transmission Mechatronic - J743- Note Always replace bolts that were tightened with an additional turn. – Tighten the bolts in steps in the sequence shown:...
  • Page 35 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 ♦ Bolts - Transmission Fluid Pan ♦ Bolts - Transmission Fluid Pump Cover ♦ O-rings - DSG ® Transmission Mechatronic - J743 ♦ Seal - Transmission Fluid Drain and Check Plug ♦...
  • Page 36 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Release and remove the connector rotary lock -1- for the Me‐ chatronic by turning it in the direction of the starter -A-. – Remove the wires and bracket from the front of the transmis‐...
  • Page 37 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Remove the pendulum support bolts -1- from the transmission. The transmission can now be pressed down slightly to remove the Mechatronic. – Touch a grounded object again before touching the Mecha‐...
  • Page 38 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Caution Never lift the Mechatronic by the sensor arm and never let it rest on the arm. Rep. Gr.34 - Controls, Housing...
  • Page 39 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 If the arm is damaged, the Mechatronic must be replaced. Installing Touch a grounded object before touching the Mechatronic ⇒ page 7 Note The DSG Transmission Mechatronic - J743- and the transmission must be the same temperature.
  • Page 40 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Hold the Mechatronic facing up. The sensor arm must not touch the sensor wheel. – Make sure the Mechatronic unit is installed correctly. – Tighten the new bolts -1 through 10- hand-tight.
  • Page 41 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Attach the cable bracket to the transmission cover -arrows- (2 M6 nuts). – Mount the new transmission fluid pump cover -A-. Tighten the new bolts -arrows- and tighten in a diagonal sequence in stages.
  • Page 42 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Remove the transmission fluid drain- and check plug -arrow-. – Install the Oil Filler - VAS6262A- into the check hole hand- tight. – Shake before opening.
  • Page 43 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Connect the Vehicle Diagnostic Tester . – Perform a basic setting on the DSG Transmission Mechatronic - J743- . Note After installing a new Mechatronic, readapt the immobilizer.
  • Page 44 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Remove the Transmission fluid drain- and check plugs -arrow- and drain the transmission fluid. A plastic overflow tube is located in this hole (with 8 mm hex socket head, tightening specification: 3 Nm).
  • Page 45 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Replace all 10 -bolts-. – Remove the Mechatronic. When handling the Mechatronic, be particularly aware of the long sensor arm. Store Mechatronic Properly 1. Mechatronic...
  • Page 46 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Caution Never lift the Mechatronic by the sensor arm and never let it rest on the arm. Rep. Gr.34 - Controls, Housing...
  • Page 47 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 If the Arm is Damaged, the Mechatronic Must Be Replaced. Installing – Replace both O-rings -arrows- on the Mechatronic connection if the old Mechatronic is going to be installed again.
  • Page 48 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – The sensor arm must not touch the sensor wheel. All of the bolts -1 through 10- must be replaced. Rep. Gr.34 - Controls, Housing...
  • Page 49 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – First install all of the bolts -1 to 10- and tighten them by hand. – Tighten all of the bolts -1 to 10- in the tightening sequence provided.
  • Page 50 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Mount the new transmission fluid pump cover -A-. Tighten the new bolts -arrows- and tighten in a diagonal sequence in stages. – Install the transmission. Refer to ⇒...

  • Page 51: Selector Mechanism

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Selector Mechanism ⇒ 2.1 Overview - Selector Mechanism , page 47 ⇒ 2.2 Emergency Release from P , page 50 ⇒ 2.3 Selector Lever Handle, Removing and Installing , page 51 ⇒...
  • Page 52 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 1 - Handle with Shift Cover ❑ Do not remove the han‐ dle unnecessarily. For emergency release, on‐ ly cover must be re‐ moved. Refer to ⇒...
  • Page 53 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 ❑ Removing and installing. Refer to ⇒ 2.6.1 Selector Lever Cable, Removing and Installing, ZF , page 63 ❑ Checking or adjusting. Refer to ⇒ 2.8 Selector Lever Cable, Checking and Adjusting , page 68 2.1.2...

  • Page 54: Emergency Release From P

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 9 - Bolt ❑ 20 Nm + 90 ❑ Replace after removing ❑ Quantity: 2 ❑ For attaching the cable bracket to the transmission 10 - Transmission 11 - Lock Washer ❑...

  • Page 55: Selector Lever Handle, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Hold the shift cover to the side and from above push the yellow plastic part and hold it in this position. The selector lever can now be moved out of P .
  • Page 56 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Caution This procedure contains mandatory replaceable parts. Refer to component overview prior to starting procedure. Mandatory Replacement Parts ♦ Clamp - Shift Handle Short Description: The handle is removed together with the shift cover.

  • Page 57: Button In Handle, Moving Into Installation Position

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Note ♦ There is the possibility that the button can be pressed into the handle. Never install the handle when the button is pressed in. Move the button in the installation position. Refer to ♦...
  • Page 58 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 There are two ways to move the button into the installation posi‐ tion, with or without assembly fastener. The following de‐ scribes both ways. Moving the Handle with an Assembly Fastener into the Instal‐...

  • Page 59: Selector Mechanism, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Push the small lever -1- into the groove -2- with a screwdriver. This pushes the button -3- into the installation position. -I- the button is in the pressed position...
  • Page 60 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Loosen the adjusting screw -arrow-. – Remove the lock washers -A and B-. The lock washers must later be replaced when adjusting selector lever cable. Use pliers to remove the lock washer -B-. Do not use a sharp- edged lever.
  • Page 61 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Install the bracket -2-. Refer to ⇒ Body Interior; Rep. Gr. 68 ; Center Console; Center Console, Removing and Installing . – Install the air guide channel from the center console. Refer to ⇒...
  • Page 62 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Remove the bracket -2-, to do this remove the left and right bolts -1-. – Disconnect the connector from the selector mechanism to the vehicle wiring harness.
  • Page 63 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Guide the cable into the selector mechanism in direction of -arrow- until the locking mechanism -arrow- is visible. – Turn the locking mechanism 90° in the direction of the -arrow- with a large screwdriver.
  • Page 64 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Install the bracket -2-. Refer to ⇒ Body Interior; Rep. Gr. 68 ; Center Console; Center Console, Removing and Installing . – Install the air guide channel from the center console. Refer to ⇒...
  • Page 65 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Remove the bracket -2-, to do this remove the left and right bolts -1-. – Disconnect the connector from the selector mechanism to the vehicle wiring harness.
  • Page 66 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Remove the bracket -A-, if equipped. – Remove the nuts -arrows- in the vehicle interior. – Remove the selector mechanism -B- with the gearshift hous‐...

  • Page 67: Selector Lever Cable, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Selector Lever Cable, Removing and In‐ stalling ⇒ 2.6.1 Selector Lever Cable, Removing and Installing, ZF , page 63 ⇒ 2.6.2 Selector Lever Cable, Removing and Installing, ECS , page 65 2.6.1...
  • Page 68 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Insert a large screwdriver into the grooves on the locking mechanism and turn 90° in the direction of the -arrow-. – Pull the cable from the selector mechanism and remove.
  • Page 69 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Install new lock washer -arrow- and replace the plugs. – Remove the cable from the transmission and secure using a new lock washer -B-. Do not install the lock washer -A- yet. It will be installed after the cable is checked and adjusted.
  • Page 70 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Loosen the adjusting screw -arrow-. – Remove the lock washers -A and B-. The lock washers must later be replaced when adjusting selector lever cable. Use pliers to remove the lock washer -B-. Do not use a sharp- edged lever.

  • Page 71: Gearshift Mechanism, Checking

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Remove the cable from the transmission and secure using a new lock washer -B-. Do not install the lock washer -A- yet. It will be installed after the cable is checked and adjusted.

  • Page 72: Selector Lever Cable, Checking And Adjusting

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 The illuminated D in the cover must turn off. The + and - must turn on. The transmission range display in the instrument cluster must change from P R N D S to 6 5 4 3 2 1 when the selector lever is moved into the Tiptronic gate.

  • Page 73: Selector Shaft Seal, Replacing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Gearshift Lever, Moving into P The transmission gearshift lever must be pushed all the way back . – Pull the transmission gearshift lever forward. – Push the transmission gearshift lever to the rear -arrow-.
  • Page 74 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Special tools and workshop equipment required ♦ Press Piece - Shift Rod/Alternator - VW423- ♦ Puller - Crankshaft/Power Steering Seal - T20143- ♦ Torque Wrench 5-50Nm - VAG1331- ♦...
  • Page 75 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 • The closed side of the gasket -arrow- points to the Press Piece - Shift Rod/Alternator - VW423- . – Install the new seal all the way. Do not tilt the gasket when installing it.

  • Page 76: Transmission, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Transmission, Removing and Instal‐ ling ⇒ 3.1 Transmission, Removing , page 72 ⇒ 3.2 Transmission, Installing , page 91 ⇒ 3.3 Transmission Tightening Specifications , page 96 Transmission, Removing ⇒...
  • Page 77 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 ♦ Engine Support - Basic Set Square Pipe - T40091/1- (quantity ♦ Engine Support - Basic Set Movable Joint - T40091/3- (quan‐ tity 2) ♦ Engine Support - Supplement Kit Spindle - T40093/3- (quan‐...
  • Page 78 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Remove the selector lever cable from the transmission -arrows-. Note Use pliers to remove the lock washer from the cable bracket. ♦ Do not use a sharp-edged lever. Otherwise the selector lever cable could get damaged.
  • Page 79 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Clamp the coolant hose with the Hose Clamps - Up To 25mm - 3094- . – Loosen the hose clamps -arrows- and remove the coolant ho‐...
  • Page 80 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Rep. Gr.34 - Controls, Housing...
  • Page 81 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 One bolt is located inside the hole for the starter -arrow-. Use Socket - Xzn 14 - T10061- to remove the bolt. – If there are hose and cable connections located near the en‐...
  • Page 82 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – If present, remove wires from the front area of both longitudinal members -arrow-. Do not disconnect line system. – Place the Engine Support Brackets - T40093/3-6- on both lon‐...
  • Page 83 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Remove the bolts -11- and then remove the pendulum support from the transmission. – Secure the subframe before removing. Refer to ⇒ Suspen‐ sion, Wheels, Steering; Rep. Gr. 40 ; Subframe; Subframe, Securing .
  • Page 84 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Remove the transmission bracket in direction of -arrow-. To remove the transmission 0D9 , the Transmission Support - 3282- is equipped with the Transmission Support - Mounting Plate - 3282/42A- and positioned on the Engine and Gearbox Jack - VAS6931- .
  • Page 85 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Slightly turn and lower the transmission. Make sure that the right flange shaft -1- is guided past when lowering the inter‐ mediate plate -arrow-. Note Pay attention to all of the lines when lowering the transmission.
  • Page 86 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 ♦ Engine Support - Supplement Kit - T40093A- ♦ Engine Bung Set - VAS 6122- Removing – Move the selector lever into »P«. – Disconnect the battery ground cable. Refer to ⇒ Electrical Equipment;...
  • Page 87 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Note Use pliers to remove the lock washer from the cable bracket. ♦ Do not use a sharp-edged lever. Otherwise the selector lever cable could get damaged.
  • Page 88 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Remove the starter -A-. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Starter; Starter, Removing and Installing . Remove the »lower« bolt first. Caution There is a risk of damaging the DSG Transmission Mecha‐...
  • Page 89 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 One bolt is located inside the hole for the starter -arrow-. Use Socket - Xzn 14 - T10061- to remove the bolt. – Remove windshield wiper arms. Refer to ⇒ Electrical Equip‐...
  • Page 90 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Attach the Engine Support Bridge - 10-222A- as follows: The following are needed: ♦ Engine Support Bridge - Engine Support 31 - Adapter 1 - 10-222A/31-1- ♦...
  • Page 91 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Remove fuel filter and set off to the side. Do not open the line system. Refer to ⇒ Rep. Gr. 20 ; Overview - Fuel Filter .
  • Page 92 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – If equipped, disconnect the connector -1- from the Oil Level Thermal Sensor - G266- . Caution Risk of damaging the decoupling element. ♦ Do not bend the decoupling element more than 10°.
  • Page 93 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Secure the driveshafts to the suspension strut using a Ten‐ sioning Strap - T10038- . Do not damage the surface of the shafts. – Remove the bolts -1 and 2- from the transmission bracket -A-.
  • Page 94 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 To remove the transmission 0D9 , the Transmission Support - 3282- is equipped with the Transmission Support - Mounting Plate - 3282/42A- and positioned on the Engine and Gearbox Jack - VAS6931- .

  • Page 95: Transmission, Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Transmission, Installing Caution This procedure contains mandatory replaceable parts. Refer to component overview prior to starting procedure. Mandatory Replacement Parts ♦ Bolts - Engine to Transmission Connecting ♦...
  • Page 96 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Place the transmission with the Transmission Support - 3282- on the Engine and Gearbox Jack - VAS 6931- . – Place the Engine and Gearbox Jack - VAS6931- under the vehicle.
  • Page 97 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Install the left subframe mount as follows: – Replace all the bolts -1 and 2-. – Install the new bolt first hand-tight. – Install the bolts -1- in the transmission bracket -A-.
  • Page 98 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Attach the pendulum support to the transmission by tightening the bolts -11-. Refer to ⇒ Rep. Gr. 10 ; Subframe Mount; Overview - Subframe Mount .
  • Page 99 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Selector lever cable lock washers -arrows- must be replaced. – Adjust the selector lever cable. Refer to ⇒ 2.8 Selector Lever Cable, Checking and Adjusting , page 68 –...

  • Page 100: Transmission Tightening Specifications

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Transmission Tightening Specifications Transmission to Engine Item Bolt M12 x 55 • With Insert Tool - 18mm T10179: 65 Nm M10 x 45 ♦ Starter to trans‐...

  • Page 101: Subframe Mount

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Subframe Mount ⇒ 4.1 Overview - Subframe Mount , page 97 Overview - Subframe Mount 1 - Bolt ❑ For the tightening spec‐ ification. Refer to ⇒ En‐...
  • Page 102 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 ❑ Transmission with threaded insert. Refer to ⇒ Fig. Transmission with Threaded Insert (for Example Heli Coil) for Attaching the Pendulum Support , page 99 ❑ For the tightening specification. Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition; Rep. Gr. 10 ;...
  • Page 103 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Transmission with Threaded Insert (for Example Heli Coil ) for Attaching the Pendulum Support Note There are threaded inserts (for example Heli Coil ) in the pen‐...

  • Page 104: Transmission, Transporting

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Transmission, Transporting Special tools and workshop equipment required ♦ Engine Sling - 2024A- ♦ Transmission Support Jig - 3336- ♦ Shop Crane - VAS6100- Always secure heaving parts when transporting them.

  • Page 105: Transmission, Disassembling And Assembling

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Transmission, Disassembling and Assembling ⇒ 6.1 Overview - Transmission , page 101 Overview - Transmission 1 - Transmission Cover ❑ Removing and instal‐ ling. Refer to ⇒...
  • Page 106 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 7 - Dual Clutch ❑ Removing. Refer to ⇒ 1.3 DSG® Clutch, Removing , page 19 ❑ Installing. Refer to ⇒ 1.4 DSG® Clutch, Installing , page 21 8 - Bleed Pipe ❑...
  • Page 107 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 25 - Transmission Oil Pump ❑ Removing and installing. Refer to ⇒ 8.2 Transmission Fluid Pump, Removing and Installing , page 107 26 - Transmission Fluid Pump Cover ❑...

  • Page 108: Securing On Engine And Transmission Holder

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Securing on Engine and Transmis‐ sion Holder Special tools and workshop equipment required ♦ Holding Plate - VW309- ♦ or Holding Plate - VW309A- ♦ Transmission Support - VW353- ♦...

  • Page 109: Transmission Fluid Circuit

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Transmission Fluid Circuit ⇒ 8.1 Transmission Fluid Cooler, Removing and Installing , page ⇒ 8.2 Transmission Fluid Pump, Removing and Installing , page ⇒ 8.3 Transmission Fluid Filter, Removing and Installing ,...
  • Page 110 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Disconnect the coolant hoses with Hose Clamps - Up To 25mm - 3094- and remove from the transmission fluid cooler. – Remove the bolts -A- and the transmission fluid cooler -B-.

  • Page 111: Transmission Fluid Pump, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Attach the coolant hoses to the transmission fluid cooler and remove the Hose Clamps - Up To 25mm - 3094- . – Install the battery and the battery tray if they were removed earlier.
  • Page 112 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Place the Used Oil Collection and Extraction Unit - SMN372500- or Drip Tray under the transmission. – Remove the Transmission fluid drain- and check plugs -arrow- and drain the transmission fluid.
  • Page 113 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Remove the bolts -arrows-. Remove the transmission fluid pump -1- from the alignment pin and the input shaft. Remove the top bolt with the Wrench - Pump/Injector Long Reach - T10054- .

  • Page 114: Transmission Fluid Filter, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 3 Bolts with Flat Head, Top Bolt -arrow- with Countersunk Head Replace the bolts after removing them. Tightening Specification ♦ Countersunk head bolt: 8 Nm without tightening angle (tighten with the Wrench - Pump/Injector Long Reach - T10054- ) ♦...
  • Page 115 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 ♦ The clutch is burned or has a mechanical fault. Note General repair instructions. Refer to ⇒ 3 Repair Information , page 5 Caution This procedure contains mandatory replaceable parts. Refer to component overview prior to starting procedure.
  • Page 116 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Loosen the filter housing -arrow- approximately seven turns. – Wait 10 seconds. This way the fluid can flow from the filter housing back into the transmission.

  • Page 117: Transmission Fluid

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Transmission Fluid ⇒ 9.1 Transmission Fluid Level, Checking , page 113 ⇒ 9.2 Transmission Fluid, Draining and Filling , page 116 Transmission Fluid Level, Checking Special tools and workshop equipment required ♦...
  • Page 118 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Shorten the Bleed Pipe on the Adapter For Oil Filling - VAS6262A- as Follows: – Shorten the pipe to dimension -a-. This assures the pipe on the Adapter For Oil Filling - VAS6262A- will not touch the bot‐...
  • Page 119 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Remove the transmission fluid drain- and check plug -arrow-. – Always replace the seal for the drain plug -arrow-. Note Even if the level of transmission fluid is too low, first a small amount of transmission fluid will flow out of the overflow tube, because it fills during operation.

  • Page 120: Transmission Fluid, Draining And Filling

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Install the Oil Filler - VAS6262A- into the check hole hand- tight. – Shake before opening. – Attach the Oil Filler - VAS6262A- to the oil bottle. Be sure to read the instructions.
  • Page 121 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 ♦ Noise insulation is removed. Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Noise Insulation; Overview - Noise Insulation . ♦ The selector level is in P.
  • Page 122 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Remove the transmission fluid drain- and check plug -arrow-. A black plastic overflow tube is located in this hole (with 8 mm hex socket head). Its length determines the oil level in the trans‐...
  • Page 123 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Tighten the transmission fluid drain and check plug -arrow- hand-tight only. – Start the engine. – Press the brake pedal and move the selector lever through each gear for approximately 3 seconds.

  • Page 124: Special Tools

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Special Tools Special tools and workshop equipment required ♦ Engine Support Bridge - 10-222A- ♦ Engine Support Bridge - Engine Support 29 - 10-222A/29- ♦ Engine Support Bridge -...
  • Page 125 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 ♦ Engine and Gearbox Jack - VAS6931- ♦ Transmission Support - Mounting Plate 42A - 3282/42A- ♦ Hose Clamps - Up To 25mm - 3094- ♦ Tensioning Strap - T10038- ♦...
  • Page 126 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 ♦ Torque Wrench 5-50Nm - VAG1331- ♦ Used Oil Collection and Ex‐ traction Unit - SMN372500- ♦ Vehicle Diagnostic Tester ♦ Shop Crane - Drip Tray - VAS6208- ♦...
  • Page 127 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 ♦ Socket - Xzn 14 - T10061- ♦ Puller - Crankshaft/Power Steering Seal - T20143- ♦ Engine Support - Basic Set Square Pipe - T40091/1- (quantity ♦...
  • Page 128 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 ♦ Engine Support Brackets - T40093/3-6- (quantity 2) ♦ Hose Clip Pliers - VAG1275A- ♦ Engine And Transmission Holder - VAS6095- ♦ Shop Crane - VAS6100-...
  • Page 129 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 ♦ Also for some oil containers Oil Filler - Adapter 6 - VAS6262/6- ♦ Holding Plate - VW309A- ♦ Transmission Support - VW353- ♦ Press Piece - Shift Rod/Alternator - VW423-...
  • Page 130 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 ♦ Engine Sling - 2024A- ♦ Transmission Support Jig - 3336- Rep. Gr.34 - Controls, Housing...

  • Page 131: Gears And Shafts

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 35 – Gears and Shafts Gears and Shafts, Disassembling and Assembling No Repairs to Gears and Shafts 1. Gears and Shafts, Disassembling and Assembling...

  • Page 132: Final Drive, Differential

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 39 – Final Drive, Differential Seals ⇒ 1.1 Component Location Overview - Seals , page 128 ⇒ 1.2 Left Seal, Replacing , page 128 ⇒ 1.3 Right Seal, Replacing , page 131...
  • Page 133 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 ♦ Seal Installer - Flange Shaft - 3305- ♦ Socket And Extended Bit - T10107A- or ♦ Long Hex Socket - VAG1669- ♦ Used Oil Collection and Extraction Unit - SMN372500- ♦...
  • Page 134 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – To remove and install the flange shaft, install 2 bolts into the flange and counterhold it using a pry bar. – Remove the flange shaft.

  • Page 135: Right Seal, Replacing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Install the seal all the way in without tilting it. Note Press the flange shaft against the transmission so that the bolt in the threaded piece of the differential touches.
  • Page 136 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Disconnect the connector -1- from the Oil Level Thermal Sen‐ sor - G266- , if equipped. – If equipped, remove the heat shield above the right drive axle -arrows-.
  • Page 137 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Secure the right drive axle to the suspension strut using a Tensioning Strap - T10038- . Do not damage the surface of the shaft. – Place the Used Oil Collection and Extraction Unit - SMN372500- or Drip Tray under the transmission.
  • Page 138 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 – Install the seal all the way in without tilting it. Note Press the flange shaft against the transmission so that the bolt in the threaded piece of the differential touches.

  • Page 139: Special Tools

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Special Tools Special tools and workshop equipment required ♦ Used Oil Collection and Extraction Unit - SMN372500- ♦ Tensioning Strap - T10038- ♦ Socket And Extended Bit - T10107A- ♦...
  • Page 140 Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 ♦ Seal Installer - Axle Flange - 3158- ♦ Seal Installer - Flange Shaft - 3305- Rep. Gr.39 - Final Drive, Differential...

  • Page 141: Revision History

    Golf 2015 ➤ , Golf Variant 2015 ➤ Direct Shift Gearbox - Edition 09.2015 Revision History DRUCK NUMBER: K0059240321 Fac‐ Edit Notes Quality tory Edi‐ Type Checke Edi‐ tion d By tion 09.2 10/1 Fac‐ Eric P. 3/20 tory Up‐...
  • Page 142 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 143 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 144 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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