Volkswagen Golf Variant 2007 Workshop Manual
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Volkswagen Golf Variant 2007 Workshop Manual

7-speed dual clutch gearbox 0am
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Service
Workshop Manual
Golf Variant 2007 ➤
Golf Variant 2010 ➤
Jetta 2005 ➤
Jetta 2011 ➤
7-speed dual clutch gearbox 0AM
Edition 07.2010
Service Department. Technical Information

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Summary of Contents for Volkswagen Golf Variant 2007

  • Page 1 Service Workshop Manual Golf Variant 2007 ➤ Golf Variant 2010 ➤ Jetta 2005 ➤ Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM Edition 07.2010 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 © 2010 Volkswagen AG, Wolfsburg MEX5R008520...

  • Page 3: Table Of Contents

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Contents 00 - Technical data ........... .
  • Page 4 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Renewing oil seal for right stub shaft ......... . 114 Renewing oil seal for left stub shaft .

  • Page 5: Technical Data

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 00 – Technical data Gearbox identification KHN - Gearbox code letters ⇒ page 2 01.06.06 - Production date:...

  • Page 6: Code, Engine Allocation

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Code, engine allocation Allocation: gearbox codes for petrol engines KHN, LKG, LKM KUT, LPL 1.4 l/90 kW TSFI 1.4 l/118 kW TSI...

  • Page 7: Capacities

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Capacities Dual clutch gearbox 0AM Mechatronic unit for dual clutch gearbox -J743- 1.7 l gear oil -G 052 171-...

  • Page 8: General Repair Notes

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 General repair notes Tools Uncertainty often occurs with smaller bolts having low tightening forces. Torque wrench 2...10 Nm -V.A.G 1783- can be used with these bolts.
  • Page 9 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Make sure no small parts drop into this hole during installation work. – Cover the hole with a cloth before installation work.

  • Page 10: Oil

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 In some vehicles, a cover is fitted over the engaging levers. The cover prevents dirt getting in.
  • Page 11 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 All “active partners” are detected once again the next time the ignition system is switched on.

  • Page 12: Clutch

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 30 – Clutch Removing and installing the dual clutch Brief description The clutch is installed “upwards” with the gearbox removed. The mechatronic unit remains on the gearbox.
  • Page 13 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 ♦ Support device -T10323- ♦ Assembly tool -T10356- ♦ Puller -T10373- ♦ Thrust piece -T10376- –...
  • Page 14 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Pull off both breather caps -arrows- and close using suitable plugs to achieve an oil-tight seal.
  • Page 15 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Remove retaining ring of clutch -arrow-. Note It is possible that the retaining ring is seated very tightly. The ♦...

  • Page 16: Adjusting Position Of Engagement Bearings "K 1 And K 2

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Remove small engagement bearing. – Remove large engaging lever. – Remove bolts and remove small engaging lever.
  • Page 17 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 ♦ Ruler -T40100- ♦ Digital depth gauge e.g. -VAS 6594- ♦ Adhesive -AMV 195 KD1 01- ♦...
  • Page 18 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 “K 1” “K 2” Note Perform the following steps “in sequence” and precisely. Adjusting: – Install parts of clutch as far as large engaging lever ⇒...
  • Page 19 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Install retaining ring of outer input shaft -arrow-. – Place a ruler -T40100- on its side on flange of clutch housing.
  • Page 20 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Measure dimension “B” again on opposite side. Note Do not measure on ring joint. This could force ring away at that point and falsify measuring result.
  • Page 21 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Measure distance from “shaft end” to gauge block -T10374- . 1. Removing and installing the dual clutch...
  • Page 22 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – To make sure this measurement is as accurate as possible, position digital depth gauge twice at opposite sides.
  • Page 23 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Calculated shim thickness Shim to be installed (in milli‐ metres) from 0.31 0.90 0.91 1.10 1.11...
  • Page 24 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – By “turning”, check whether small engagement bearing is in‐ stalled correctly and that grooves are seated correctly.
  • Page 25 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – To make sure this measurement is as accurate as possible, position digital depth gauge twice at opposite sides.

  • Page 26: Installing Dual Clutch

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Calculated shim thickness Shim to be installed (in milli‐ metres) from 0.31 0.90 0.91 1.10 1.11...
  • Page 27 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 ♦ Assembly tool -T10356- ♦ Puller -T10373- ♦ Thrust piece -T10376- ♦ Adhesive -AMV 195 KD1 01-...
  • Page 28 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Insert plastic retainer of engaging lever and check for correct seating. – Install small engaging lever with clip.
  • Page 29 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Insert small engagement bearing with measured shim. Shim should be under small engagement bearing. Therefore, in‐...
  • Page 30 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Insert clutch. – Use puller -T10373- to insert clutch into gearbox. – Turn spindle “back” first.
  • Page 31 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – To enable clutch to find its installation position already, turn clutch against puller -T10373- by hand.
  • Page 32 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Insert retaining ring for hub -arrow-. Installation position: Joint of ring must point towards “hub” on clutch.
  • Page 33 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Remove clutch again in this case ⇒ page 8 – Look at shims -arrows- precisely.

  • Page 34: Controls, Housing

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 34 – Controls, housing Renewing gear oil The gearbox is filled for life. Therefore, there is no need to check the oil level of this gearbox.
  • Page 35 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Remove securing clip in -direction of arrow-. Securing clips for selector lever cable must always be renewed.
  • Page 36 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Note Grease oil seal in cover with sealing grease -G 052 128 A1- . – Always renew bolt of lever.

  • Page 37: Selector Mechanism

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Selector mechanism WARNING Before working on vehicle with engine running, move selector lever into position “P” and apply handbrake.

  • Page 38: Removing And Installing Selector Lever Cable - Vehicles Up To 02.2009

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 ❑ Do not grease 5 - Locking plate ❑ Always renew after removing 6 - Nut ❑...
  • Page 39 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Remove securing clip in -direction of arrow-. Securing clips for selector lever cable must always be renewed.
  • Page 40 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 -Selector housing- is pushed forwards slightly on cable. Rep. Gr.34 - Controls, housing...
  • Page 41 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 To remove cable, securing tab must be pushed forwards -arrow 1-. – At same time, push -pin- up with a screwdriver -arrow 2-.
  • Page 42 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Clarification: ♦ -Arrow 1- Push tab forwards ♦ -Arrow 2- Push pin up – Remove selector lever cable.
  • Page 43 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Ensure that selector lever cable is properly routed during in‐ stallation. If the sheet metal is bent downwards, it may cause noises. The cable will vibrate against the sheet metal.
  • Page 44 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Remove selector housing, heat shield and exhaust system ⇒ Rep. Gr. 26 ; Removing and installing parts of exhaust sys‐...

  • Page 45: Overview Of Selector Mechanism - Vehicles From 03.2009 Onwards

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Overview of selector mechanism - vehicles from 03.2009 onwards 1 - Selector cover with handle ❑...

  • Page 46: Removing And Installing Selector Mechanism With Selector Lever And Selector Lever Cable

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Removing and installing selector mech‐ anism with selector lever and selector lever cable - vehicles from 03.2009 on‐...

  • Page 47: Checking Selector Lever Cable

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Remove selector mechanism. Install in reverse order of removal. – Before you put on ball head: check cable ⇒...
  • Page 48 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 ♦ Torque wrench -V.A.G 1331- The selector lever cable must always be adjusted whenever ♦ The selector lever cable has been removed from the gearbox.
  • Page 49 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 This figure shows you the view of gearbox from “behind”. -P- in direction of cable support bracket.

  • Page 50: Emergency Release Of Selector Lever

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Emergency release of selector lever Do not remove handle. – Unclip selector cover and hold to side.
  • Page 51 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Push sleeve upwards to release handle. – Lock the handle again after installing. To do this, press the sleeve under the handle back down.

  • Page 52: Checking Selector Mechanism

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – However, should this happen, unclip handle trim upwards. – Press small lever for pull rod -arrow- back into groove before installing handle.
  • Page 53 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Symbols must change from “P R N D S” to “7 6 5 4 3 2 1”.

  • Page 54: Mechatronic Unit For Dual Clutch Gearbox J743

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Mechatronic unit for dual clutch gear‐ box -J743- Safety note on mechatronic unit for dual clutch gearbox -J743- ⇒...

  • Page 55: Overview - Mechatronic Unit

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 WARNING Do not work on pressure accumulator. The accumulator is un‐ der pressure and is not allowed to be opened.

  • Page 56: Removing Mechatronic Unit For Dual Clutch Gearbox J743 With Gearbox Installed

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Removing mechatronic unit for dual clutch gearbox -J743- with gearbox in‐ stalled This description only applies to installed gearboxes. If gearbox has been removed, first remove clutch then mechatronic unit.
  • Page 57 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Note ♦ The clutch is self-adjusting. Shocks can have an effect on this adjusting device. Even if the mechatronic unit has been re‐...
  • Page 58 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 In some vehicles, a cover is fitted over the engaging levers. The cover prevents dirt getting in.
  • Page 59 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Using a screwdriver, carefully unclip gearbox input speed sender 3 -G641- from housing in -direction of arrow-.
  • Page 60 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Insert assembly lever -T10407- to its right. Rep. Gr.34 - Controls, housing...
  • Page 61 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Far enough until groove lines up with housing rib -arrow-. 3. Mechatronic unit for dual clutch gearbox J743...
  • Page 62 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 No further. – Assembly lever -T10407- should make contact with gearbox housing with its entire “rear face”.
  • Page 63 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Turn assembly lever -T10407- anticlockwise. In this way, engag‐ ing levers are pressed away from plungers -direction of arrow-.
  • Page 64 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 If lever slips off, this indicates you applied a bit of leverage to handle whilst turning.
  • Page 65 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Apply a bit of force to tip of lever when turning. This stops lever from slipping out when turning.

  • Page 66: Moving Mechatronic Unit For Dual Clutch Gearbox J743 Into "Removal Position" By Hand

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Sometimes, the mechatronic unit cannot be removed. In this case, the gear actuator is “caught” at the “top left” of the gearbox housing.
  • Page 67 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 • Only if you cannot set the mechatronic unit to removal position with the vehicle diagnostic tester , you must move the unit by hand to this position.
  • Page 68 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Remove securing clip in -direction of arrow-. Securing clips for selector lever cable must always be renewed.

  • Page 69: Installing Mechatronic Unit For Dual Clutch Gearbox J743

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Grease oil seal in cover with sealing grease -G 052 128 A1- . – Fit cover and lever again.
  • Page 70 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Note A “new” mechatronic unit is correctly filled with oil. ♦ Do not drain oil. A “removed” mechatronic unit is sent back ♦...
  • Page 71 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Every selector fork has 3 positions: “gear selected - neutral - gear selected”. – Also, move each fork into each position in succession. Then disengage all gears and return selector forks to middle position “neutral”.
  • Page 72 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Caution Handle with care. When levering the plungers out of the me‐ chatronic unit, make sure that you do not brace yourself on the sensors.
  • Page 73 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Watch out for seal on mechatronic unit. Seal must be pushed in all around.
  • Page 74 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Turn assembly lever -T10407- clockwise and remove it. – Install gearbox input speed sender 3 -G641- .
  • Page 75 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 In some vehicles, a cover is fitted over the engaging levers. The cover prevents dirt getting in.

  • Page 76: View Of Selector Forks With Mechatronic Unit Removed

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 View of selector forks with mechatronic unit removed N - Idling/gearbox neutral po‐ sition “in the middle”...

  • Page 77: Removing And Installing Gearbox

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Removing and installing gearbox Information about gearboxes with different output shafts ⇒ page 73 Vehicles with petrol engines 1.4 l/90 kW TFSI engine and 1.4 l/118 kW TSI engine...

  • Page 78: Removing Gearbox, Vehicles With 1.4 L/90 Kw Tfsi Engine And 1.4 L/118 Kw Tsi Engine

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Removing gearbox, vehicles with 1.4 l/90 kW TFSI engine and 1.4 l/118 kW TSI engine...
  • Page 79 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Noise insulation beneath engine/gearbox, lower cover in front left wheel housing and pendulum support are removed “from below”.
  • Page 80 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Release mechatronic unit connector by pulling and pull off connector. – Now remove all upper connecting bolts between engine and gearbox.
  • Page 81 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 A bolt is located in the starter motor hole. Bit -T10061- can be used instead of an 18 mm socket.
  • Page 82 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Unbolt only left suspension link from swivel joint -arrows-. – Swing left drive shaft into wheel housing onto longitudinal member.
  • Page 83 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Remove front exhaust pipe so that lower bolts can be removed -arrows-. – Remove engine cover from cylinder head.
  • Page 84 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Place both remaining attachments onto gearbox as shown. When doing this, place sheet metal of drift under gearbox housing and not under mechatronic unit.

  • Page 85: Removing Gearbox, Vehicles With 1.6 L/75 Kw Mpi Engine

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Removing gearbox, vehicles with 1.6 l/75 kW MPI engine Special tools and workshop equipment required ♦...
  • Page 86 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 ♦ Adapter -10 - 222 A /3- ♦ Engine and gearbox jack -V.A.G 1383 A- Brief description The gearbox is removed downwards separately, without engine.
  • Page 87 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Remove securing clip in -direction of arrow-. Securing clips for selector lever cable must always be renewed.
  • Page 88 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 A bolt is located in the starter motor hole. Bit -T10061- can be used instead of an 18 mm socket.
  • Page 89 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Remove all retainers and brackets from front of gearbox. – Remove pendulum support. – If fitted, remove the heat shield over the right-hand drive shaft.
  • Page 90 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Secure both drive shafts to suspension struts using tensioning straps -T10038- . – Remove right flange shaft of gearbox.
  • Page 91 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Bolt bracket -T10346- to rear of the 3 mounting holes for bat‐ tery tray.
  • Page 92 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Connect left support eye on engine to support bracket . – Connect bracket -T10346- to support bracket (⇒ previous il‐...
  • Page 93 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Renew needle bearing in crankshaft -arrow- ⇒ Rep. Gr. 13 ; Crankshaft, pulling needle bearing from crankshaft and driving in .

  • Page 94: Removing Gearbox - Vehicles With 1.9 L/77 Kw Tdi Pd Engine

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Removing gearbox - vehicles with 1.9 l/77 kW TDI PD engine Special tools and workshop equipment required ♦...
  • Page 95 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 ♦ Hook -10 - 222 A /2- ♦ Shackle -10 - 222 A /12- ♦ Engine and gearbox jack -V.A.G 1383 A- Brief description The gearbox is removed downwards separately, without engine.
  • Page 96 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Step on the brake pedal while a 2nd mechanic loosens the two drive shaft bolts -arrow-.
  • Page 97 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Remove noise insulation ⇒ Rep. Gr. 50 ; Assembly overview - noise insulation .
  • Page 98 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Unscrew left suspension link from swivel joint. – Swing left drive shaft into wheel housing onto longitudinal member.
  • Page 99 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Remove pendulum support. – Remove engine cover from cylinder head. – If there are hose and cable connections in area of engine sup‐...
  • Page 100 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 To remove gearbox 0AM, set up gearbox support -3282- with ad‐ justment plate -3282/59- and push onto engine and gearbox support -V.A.G 1383 A- .

  • Page 101: Removing Gearbox - Vehicles With 1.6 L/77 Kw Tdi Cr Engine

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 In some cases, there are retainers on the front of the gearbox. – Remove retainers if installing a “new” gearbox, because there are no retainers on a “new”...
  • Page 102 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 ♦ Adapter -10 - 222 A /3- ♦ Adapter -10 - 222 A /18- ♦ Engine and gearbox jack -V.A.G 1383 A- Brief description The gearbox is removed downwards separately, without engine.
  • Page 103 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Remove battery and battery tray ⇒ Rep. Gr. 27 ; Battery; Removing and installing battery .
  • Page 104 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Remove noise insulation ⇒ Rep. Gr. 50 ; Assembly overview - noise insulation .
  • Page 105 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Unscrew left suspension link from swivel joint. – Swing left drive shaft into wheel housing onto longitudinal member.
  • Page 106 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Remove pendulum support. – If there are hose and cable connections in area of engine sup‐...
  • Page 107 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Remove all bolts -1- and -2- for bracket. – Then lower engine and gearbox slightly using spindles of sup‐...

  • Page 108: Installing Gearbox

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Renew needle bearing in crankshaft -arrow- ⇒ Rep. Gr. 13 ; Crankshaft, pulling needle bearing from crankshaft and driving in .
  • Page 109 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 In some vehicles, a cover is fitted over the engaging levers. The cover prevents dirt getting in.
  • Page 110 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – If it has not already been done, renew needle bearing in crank‐ shaft -arrow- ⇒ Rep. Gr. 13 ; Crankshaft, pulling needle bearing from crankshaft and driving in .

  • Page 111: Torque Settings "Gearbox To Engine" And Notes On Assembly Mounting

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Ensure that selector lever cable is properly routed during in‐ stallation -arrow-. If the sheet metal has been bent downwards when the gearbox was removed, it may cause noises.
  • Page 112 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – The bracket can be moved within its seat with a screwdriver when bolts -2- are tightened. Torque setting of -bolts 2-: 60 Nm + 90°.
  • Page 113 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 4.7.2 Engine: 1.9 l/77 kW TDI PD M12 - 80 Nm ❑ If 18 mm insert -T10179- is used: 65 Nm.
  • Page 114 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 4.7.3 Engine: 1.6 l/77 kW TDI CR M12 - 80 Nm ❑ If 18 mm insert -T10179- is used: 65 Nm.

  • Page 115: Transporting Gearbox And Securing To Assembly Stand

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Transporting gearbox and securing to assembly stand Transporting gearbox – Pull off both breather caps -arrows- and close using suitable plugs to achieve an oil-tight seal.
  • Page 116 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Lift gearbox into assembly stand. The gearbox is lifted “into assembly stand” together with gearbox support -VW 353- .

  • Page 117: Gears, Shafts

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 35 – Gears, shafts Currently, no repairs can be made to gears and shafts 1. Currently, no repairs can be made to gears and shafts...

  • Page 118: Final Drive - Front Differential

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 39 – Final drive - front differential Oil seals Gearbox with stub shafts -A-. Right ⇒...
  • Page 119 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 ♦ Sealing grease -G 052 128 A1- ♦ Drip tray Perform the following steps: Note Do not remove both drive shafts from gearbox at the same ♦...

  • Page 120: Renewing Oil Seal For Left Stub Shaft

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 Renewing oil seal for left stub shaft Right side ⇒ page 114 Special tools and workshop equipment required ♦...
  • Page 121 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 ♦ Torque wrench -V.A.G 1332- ♦ Sealing grease -G 052 128 A1- ♦ Drip tray...

  • Page 122: Renewing Seal For Right Flange Shaft

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Drive in new seal to stop, being careful not to cant seal. If necessary, it is possible to press a new dust ring onto the stub shaft using drift sleeve -40 - 20- .
  • Page 123 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 ♦ Torque wrench -V.A.G 1332- ♦ Sealing grease -G 052 128 A1- ♦ Drip tray...

  • Page 124: Renewing Oil Seal For Left Flange Shaft

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Drive in new seal to stop with thrust piece -3305- , being careful not to cant seal.
  • Page 125 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 ♦ Hexagon key -T10107 A- or socket and extended bit -V.A.G 1669- ♦ Torque wrench -V.A.G 1331- ♦...
  • Page 126 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Only unscrew left suspension link from swivel joint. – Unscrew nut -1- from coupling rod -3- ⇒ Rep. Gr. 40 ; As‐...
  • Page 127 Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 7-speed dual clutch gearbox 0AM - Edition 07.2010 – Half-fill space between sealing lip and dust lip of new seal with sealing grease -G 052 128- -arrow-.

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