D4B804111B4-Direct Shift Gearbox

Service
Repair Manual
Golf 2015
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - General, Technical Data
30 - Clutch
34 - Controls, Housing
35 - Gears and Shafts
39 - Final Drive, Differential
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Technical information should always be available to the foremen and mechanics, because their cop Vo
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careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
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safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright 2016 Volkswagen AG, Wolfsburg D4B804111B4

Golf 2015 , Golf Variant 2015
Direct Shift Gearbox - Edition 09.2015
Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Transmission Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 General Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Start/Stop System Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Safety Precautions when Tow Starting and Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4 Safety Precautions during Road Test with Testing Equipment . . . . . . . . . . . . . . . . . . . . . . 4
3 Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Seals, Sealing Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Bolts and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1 Transmission/Engine Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.3 Gear Ratio Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.1 Component Location Overview - Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . .. .V.ol.ks. w. a.g.e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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30 - Clutch . . . . . . . . . . . . . . . . . .d b.y. . . . . . . . . . . . . . . . . . . . o.t g.u.ara. . . . . . . . . . .
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1 Clutch . . . . . . . . . . . . .u.tho. r. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . t.ee. o. . . . . . . . . .
...... 13
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1.1 Overview - Dual Clutch ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .c. . . . . . . .
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1.2 Clutch End Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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1.3 DSG Clutch, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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1.4 DSG Clutch, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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34 - Controls, Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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1 Mechatronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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1.1 Overview - Mechatronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

1.2 Mechatronic, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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2 Selector Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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2.1 Overview - Selector Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

2.2 Emergency Release from P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
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2.3 Selector Lever Handle, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

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2.4 Button in Handle, Moving Into Installation Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

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2.5 Selector Mechanism, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

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2.6 Selector Lever Cable, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

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2.7 Gearshift Mechanism, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

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2.8 Selector Lever Cable, Checking and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

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2.9 Selector Shaft Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

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3 Transmission, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
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3.1 Transmission, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
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3.2 Transmission, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
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3.3 Transmission Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4 Subframe Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
4.1 Overview - Subframe Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5 Transmission, Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Contents i
6 Transmission, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

6.1 Overview - Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
7 Securing on Engine and Transmission Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
8 Transmission Fluid Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
8.1 Transmission Fluid Cooler, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
8.2 Transmission Fluid Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
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8.3 Transmission Fluid Filter, Removing and Installing k.s.w.ag.e.n.A.G. . . . . . . .n .AG . .do. e.s .n . . . . . . . . . 110
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9 Transmission Fluid . . . . . . . . . . . . . . . . . . . .e.d .b . . . . . . . . . . . . . . . . . . . . . . . . . . .u.ar.an. . . . .
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9.1 Transmission Fluid Level, Checking . . . u.th.or. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . e. e.or. . 113
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9.2 Transmission Fluid, Draining and Fillingss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c. 116
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10 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
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35 - Gears and Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
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1 Gears and Shafts, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
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39 - Final Drive, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
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1 Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
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1.1 Component Location Overview - Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1.2 Left Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
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1.3 Right Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
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2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

3 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
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1 Identification
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1.1 Transmission Identification, page 1 .
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GKF - Transmission Code
10.05.2 - 05/10/2002
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14 - Plant Code
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14 15 - Time
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001 - Serial Number

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1. Identification 1
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Reading the Transmission Code on the TransmissionbyInstalled
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To read the transmission code letters under theuthconsole directly
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ported. The left subframe mount transmission bracket -A- must
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aged. Transmission Bracket, Removing and Installing. Refer to
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Additionally the transmission code it on top of the transmission
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The transmission code is also listed in the vehicle data plates.
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2 Rep. Gr.00 - General, Technical Data

2 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
4.
2.4 Safety Precautions during Road Test with Testing Equip
ment, page 4 .
2.1 General Safety Precautions

Observe the following to Avoid Personal Injury and Vehicle Dam
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There is a risk of injury and accident from accidentally engag
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Move the selector lever into P and set the parking brake
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To Prevent Personal Injury and Damage to Electrical and Elec
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tronic Components, Observe the Following:
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Connect and disconnect test equipment only when the ignition
is off.
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Complete the steps for disconnecting the battery.

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Always turn off the ignition before disconnecting the bat

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Disconnect the battery. Refer to Electrical Equipment; Rep. C py
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Gr. 27 ; Battery; Battery, Disconnecting and Connecting .
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2.2 Start/Stop System Safety Precautions
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When Working on Vehicles with Start/Stop, Note the Following:
WARNING
Danger of injury through automatic motor starting with vehicles

with the Start/Stop System.
For vehicles with an activated Start/Stop System (recog
nizable from a notification in the instrument cluster), the
motor can be started automatically if needed.
Always make sure the Start/Stop System is disabled when
working on the vehicle (turn off ignition, if needed, turn the
ignition back on).
2. Safety Precautions 3
2.3 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).
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The engine cannot be tow started, for example,
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too weak or if the starter is not working.
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2.4 Safety Precautions during Road Test
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If Testers and Measuring Equipment Must Be Used during a Test
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Drive, Follow the Points Below:
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WARNING
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There is a risk of an accident due to distractions and improperly
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secured testing equipment.

The front passenger airbag poses a risk if it deploys during an
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Always secure testing equipment on the rear seat using a
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3 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 .
3.5 Bolts and Nuts, page 8 .
3.1 General Information

Transmission
The flywheel transfers the engine torque to the double clutch.
The flywheel and the dual clutch are connected via splines.
Together they assume the function of the dual-mass flywheel.
The transmission is built like a 6-gear manual transmission.
The alternating hydraulic actuation of the double clutch per
mits operation similar to that of an automatic transmission.
This means the gears are automatically or manually shifted via
the Tiptronic mode. Clutch pedal is not available.
Selector Mechanism
In contrast to the automatic transmission, the selector lever po
sition is no longer transmitted mechanically to the transmission
via the selector lever cable and Multi-Function Transmission
Range (drive position sensor). Selector lever positions and shifts
are transmitted via a separate control module in the selector
mechanism to the transmission control module via the CAN-Bus.
The shift occurs without a cable. The selector lever cable is me
chanically brought into the park brake in the selector lever position
P.
Shift Point Changes on Inclines and Declines
An additional gear change map automatically selects the gear
changes for gradients dependent upon accelerator pedal position
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The gear change map for extreme uphill rstretches
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The gear change map for extreme downhill stretches is match
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Direct gear selection by way of the Tiptronic function permits

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3.2 Clean Working Conditions

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Always clean the connection points and the area around them
first, and then loosen them.
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Seal all open lines and connections immediately with clean

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plugs or caps from the Engine Bung Set - VAS6122- .

Place removed parts on a clean surface and cover them so
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that they do not get dirty. Use foil and paper. Use a lint-free
cloth.
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Always make sure that no dirt enters an open transmission.

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Only install clean components. Install replacement parts im

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mediately after removing them from their packaging.

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Cover all opened components carefully if it necessary to per

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3. Repair Information
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Protect the disconnected connectors from dirt and moisture

and only connect when they are dry.
3.3 General Repair Information

Carefulness, cleanliness and the correct tools are required for
transmission repairs to be successful. The usual basic safety pre
cautions also, naturally apply when carrying out vehicle repairs.
A number of generally applicable instructions for individual repair
operations, which are otherwise mentioned at various points in
the Workshop Manual, are summarized here. They apply to this
repair manual.
Guided Fault Finding, On Board Diagnostics (OBD) and Test In
struments
Before starting any repairs on the transmission, determine the
cause of the damage as accurately as possible. Refer to Ve
hicle Diagnostic Tester , Guided Fault Finding , OBD or
Test Instruments .
Special Tools and Equipment

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Always make sure that no dirt or contaminantss enter an open
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transmission. Any dirt that enters can cause transmission failure,

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especially if the DSG Transmission Mechatronic - J743- and/or
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the transmission fluid pump are open.
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Do not run the engine and do not tow the vehicle if the trans
wit
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mission cover is removed or if there is no transmission fluid
h re
hole
inside the transmission.
spec
es, in part or in w
Always clean the connection points and the area around them
t to the co
first, and then loosen them.
When installing transmission, make sure centering sleeves
rrectness of i
are correctly seated between engine and transmission.
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Circlips
Do not overstretch the circlips. nf
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Replace damaged or stretched circlips.

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The circlips must fit completely inside the groove.

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Transmission Fluid, Environmental and Disposal Regulations.

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The quality of transmission fluid is crucial to transmission function.

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The drained transmission fluid must not be used again.
Dispose of drained transmission fluid correctly.
Follow the legal environmental and disposal regulations.
Observe the information on oil the packaging.

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.
Electrical Components
Due to an electrostatic charge to the human body, a person can
receive an electrostatic shock when metal objects are touched.
This charge can damage the electrical/electronic components on
the transmission and the selector mechanism.
Touch a grounded object, such as, a water pipe or a vehicle
hoist, before working on electrical/electronic components. Do
not touch connector or open electronic components directly.
AG. Volkswagen AG d
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3.4 Seals, Sealing Rings
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Replace the O-rings, seals and gaskets.

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After removing seal rings and seals, always inspect the con
ot p
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tact surfaces at housing or shaft for burrs resulting from re

is n
h re
moval, or for other signs of damage.

ole,
spec
Before installing the seal rings, lightly oil the outer circumfer
t to the co
ence and fill the space between the sealing lips -arrow- half
way with Grease - G 052 128 A1- .
The open side of the seals point toward the fluid to be sealed
rrectne
in.
Use DSG transmission fluid only. Other lubricants cause
ss o
malfunctions.
cial p
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Coat the O-rings with DSG transmission fluid before inserting

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atio
to prevent crushing rings during installation.

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After replacing the seals, O-rings and sealing rings, check the
or
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transmission fluid level and fill if necessary. Refer to

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9.1 Transmission Fluid Level, Checking, page 113 .

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3. Repair Information 7
3.5 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.
Use a wire brush to clean the threads of bolts that were
screwed in with locking compound. Install the bolts with Lock
ing Fluid - AMV 185 101 A1- .
Use a thread cutter to clean all threaded holes containing self-
locking bolts to remove any locking compound residue. Oth
erwise the bolts could shear the next time they are removed.
Please make sure that the thread pitch is correct so that the
proper thread cutter is used during cleaning, and the thread
does not get damaged.
Always replace self-locking nuts and bolts.
AG. Volkswagen AG d
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4 Technical Data
4.1 Transmission/Engine Allocation, page 9
4.2 Capacities, page 9
4.3 Gear Ratio Calculation, page 10
4.1 Transmission/Engine Allocation

Always use refer to the transmission code letters if a repair re
quires original parts.
S tronic Transmission 0D9, Gasoline engines
Transmission Codes
PUL, PZQ, QML, RVS PUL, PZQ, QMQ,
QMQ, QSJ, QSQ, QSJ, RVS
RHN, RVS, RVW
Engine 2.0L - 162 kW TFSI 2.0L - 169 kW TFSI 2.0L - 155 kW TFSI
Refer to the Parts Catalog for the following information.
Production time period.
The individual gear ratios
agen
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Flange shaftedallocation
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Always use refer to the transmission code letters if a repair re

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S tronic Transmission 0D9, Diesel engines

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Transmission Codes
PZN, PUG, QMM,
hole
QSD
spec
es, in part or in w
Engine 2.0L - 110 kW TDI

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Common Rail
Refer to the Parts Catalog for the following information.
rrectness of i
Production time period.

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The individual gear ratios

Flange shaft allocation
nform
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4.2 Capacities
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Capacities DSG transmission 0D9

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Refill Refer to Fluid Capacity Tables; Rep. Gr. 03
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Change after removing and installing the Refer to Fluid Capacity Tables; Rep. Gr. 03
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Mechatronic with the transmission installed
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Change Interval Refer to the Maintenance tables .

Grease DSG transmission fluid. Refer to the Parts Catalog.
Transmission fluid is obtainable as a replacement part. Refer to
the Parts Catalog for the part number.
4. Technical Data 9
4.3 Gear Ratio Calculation

Example:
6th Gear Final Drive
Drive gear ZG1 = 45 ZA1 = 21
Driven gear ZG2 = 28 ZA2 = 70
i = Z2 : Z1 (Z1 = number of teeth on the drive gear, Z2 = number

of teeth on the driven gear)
iG = gear ratio = ZG2 : ZG1 = 28 : 45 = 0.622
iA = axle ratio = ZA2 : ZA1 = 70 : 21 = 3.333
itotal = total ratio = iG x iA = 0.622 x 3.333 = 2.073
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5 Electrical Components
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5.1 Component Location Overview - Electrical Components d by Volksw not
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1 - DSG Transmission Mecha ss c
tronic - J743-
ce
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un
pt
an
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Installed behind the
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transmission cover
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Removing and Instal
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ling. Refer to
h re
1.2 Mechatronic, Re
ole,
spec
moving and Installing,
page 30 .
t to the co
2 - Selector Lever - E313-
With Selector Lever
rrectne
Sensor System Control
Module - J587- , Shift
s
Lock Solenoid - N110-
s o
and Selector Lever Park
cial p
f in
Position Lock Switch -
form
mer
F319- .
atio
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The components are in

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tegrated in the circuit
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board for the shift mech

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cannot be replaced indi

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Checking. Refer to the
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Vehicle Diagnostic p by
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Gearshift mechanism,
removing and installing.
Refer to
2.5 Selector Mecha
nism, Removing and In
stalling, page 55
3 - Transmission
5. Electrical Components 11
6 Special Tools
Special tools and workshop equipment required
Not Illustrated:
Engine Support Bridge - 10-222A-
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30 Clutch
1 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
1.4 DSG Clutch, Installing, page 21
1.1 Overview - Dual Clutch

Short Description
The clutch contains two disc packs. The outer, larger disc pack
is called K 1 (clutch 1). The nK
AG1
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lkswagreverse
en AG gear and 1st,
3rd and 5th gears. lkswageinner, smaller K 2
The does
(clutch
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Assembling eo
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h
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all of the components were balanced to each other at the c
s
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manufacturer. When positioning components during installa

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tion, do no rotate them from their original position, otherwise
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imbalances will occur, reducing the shift comfort and the life
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Replacement Part Package

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1. Clutch 13
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 in the
clutch.
The
drive plate must re
main engaged between
the teeth of the outer
clutch plate carrier.
Ifthe drive plate is loos
ened, the clutch plates in
the dual clutch can slip
out of place. The dual
clutch may not be cor
rectly set during installa
tion under certain circum
stances. AG. Volkswagen AG d
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2 - Circlip orise nte
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Quantity: 10, swith
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When installing the dual

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termined. Refer to
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page 24
hole
spec
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3 - Clutch End Cover

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4 - Circlip
For clutch end cover
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Individual Parts of the Disassembled DSG Clutch

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14 Rep. Gr.30 - Clutch

AG. VGolf 2015
olkswa do,eGolf Variant 2015
gen AG
agen
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1 - DSG Clutch/Clutch Hous tho eo
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Outer clutch pack carri
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2 - Seals
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Quantity: 4
h re
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3 - Inner Clutch Pack Carrier
spec
Do not remove
t to the co
Caution
rrectne
Do not lift or remove the
inner clutch pack carrier,
s
under any circumstan
s o
cial p
f
ces. The clutch discs
inform
could rotate themselves.
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4 - Outer Discs
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Quantity: 4
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5 - Inner Discs
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6 - Thrust Washer
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7 - Circlip cted agen
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In the event the securing
ring was removed in or
der to reinsert discs, it
should be replaced with
a new ring of the same
thickness.
8 - Circlip
After installing a new du
al clutch, redetermine
the thickness. Refer to
page 24 .
9 - Drive Plate
10 - Circlip
Replace after removing
1.2 Clutch End Cover, Removing and Instal

ling
Clutch Cover Plate Guide Sleeve - T10302-
Caution
This procedure contains mandatory replaceable parts. Refer

to component overview prior to starting procedure.
Mandatory Replacement Parts

Clutch End Cover
Circlip - Clutch End Cover
1. Clutch 15
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. Remove the circlip and pry out the clutch
cover. Always replace the clutch cover and the circlip. Never use
G. Volkswagen AG d
a hammer to install the clutch cover and never lubricate w agthe
en Acenter oes
olks will certainly
seal or touch it. If this should occur, the clutch bcover
not
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To remove and install the clutch end cover,
ss
a the transmission must ra
c
be secured in a vertical position on the assembly stand. Refer to
ce
e
nl
pt
7 Securing on Engine and Transmission Holder, page 104 .
du
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Removing
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Drain the transmission fluid. Refer to
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9.2 Transmission Fluid, Draining and Filling, page 116 .
h re
hole
spec
Remove the transmission. Refer to
es, in part or in w
3.1 Transmission, Removing, page 72 .
t to the co
Secure the transmission on the assembly stand. Refer to
5 Transmission, Transporting, page 100 .
rrectness of i
If necessary change the transmission fluid filter. Refer to
l purpos
8.3 Transmission Fluid Filter, Removing and Installing,

page 110 .
nf
ercia
o
Pry out and remove the circlip -2- for the clutch cover with a
rm
m
atio
screwdriver -1- in the direction of -arrow-.
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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.
Note
The clutch end cover that was removed cannot be installed again.
AG. Volkswagen AG d
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Installing
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Caution
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Always replace the clutch end cover and the locking ring. Never
spec
use a hammer to install the clutch cover and never lubricate t to the co
the center seal or touch it. Leaks will develop. rrectness o
cial p
f inform
Only hold the clutch end cover as shown in this illustration!

mer
atio
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Note the Following Before Installing the Clutch End Cover:

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The new clutch cover must not have any oil in the around the
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center seal and it must be dry.

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If necessary, clean the sealing surface on the drive plate

-arrow- thoroughly.
Do not apply adhesive to inside of clutch end cover.
Carefully remove the adhesive if it has already been applied!
Only coat outer edge of seal with oil.
1. Clutch 17
AG. Volkswagen AG d
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Clean the Clutch Cover Plate by V Guide Sleeve - T10302- before
o gu
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using, do not use any scratched
rised
sleeves nte
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Place the sleeve son
s a level surface.
a ra
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The center seal on the new clutch end cover must now be per
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formed:
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Guide the clutch end cover horizontally and evenly over the
rrectness of i
whole sleeve in direction of -arrow-. This brings the sealing lip
into its installed position.
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Remove the sleeve upward out of the clutch end cover and
nform
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place it on the end of the dual clutch shaft.

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Guide the cover horizontally over the sleeve and press it even
ly onto its seat.
Caution
The clutch end cover may not be exposed to direct hammer

hits. If the cover is hit in any way, leakage will definitely occur.
The cover can be pried out of its seat using a screwdriver to install
the new circlip -arrow-.
Install the new circlip.

Only remove bushing once circlip is installed.

Install the transmission. Refer to
3.2 Transmission, Installing, page 91 .
Fill with transmission fluid. Refer to
9.2 Transmission Fluid, Draining and Filling, page 116 .
WARNING
Do not start the engine if there is no transmission fluid in the

transmission.
After installing the transmission, perform the Basic Set-

ting using the Guided Functions . Refer to Vehicle Diag
nostic Tester .
1.3 DSG Clutch, Removing

Brief Description
Adjust the dual clutch axial play when installing.
Secure the transmission to the assembly stand so that it is
vertical when removing and installing the dual clutch. Refer to
7 Securing on Engine and Transmission Holder,
page 104 . This is the only position in which the dual clutch
axial play can later be adjusted without error.
The large plate carrier is inserted in all clutch plates in the dual
clutch. The large plate carrier must not slide out of the lowest
plate.
Transmission fluid pump shaft is removed.
Do not install any wavy circlips
Removing AG. Volkswagen AG d
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Remove the clutch end scover.
ed b Refer to ara
nte
1.2 Clutch End Cover,
hori
Removing and Installing, page 15 . eo
aut ra
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Caution
un
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A used clutch must not be installed again.

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Removed circlips are also not installed again.

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1. Clutch 19
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

Verify that the protruding tab -arrow- of the drive plate is posi
tioned between the color-marked teeth of the outer clutch pack
carrier.
If no marking is available:
Mark the location of the tab to the outer clutch pack carrier
circumference with a waterproof marker as shown in the illus
tration. AG. Volkswagen AG d
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When installing, the drive plate tab must be placed back by V on
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Remove the drive plate in the direction of -arrows-.

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Remove the circlip -arrow- and dispose of it.
Note
G. Volkswagen
This circlip must be
lkswreplaced and re-measured
agen
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ss
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un
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Carefully remove the DSG clutch. Make sure that no other
an
d
itte
parts of the clutch fall out; for this reason, never turn over the
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clutch!
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Remove the DSG clutch.
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Remove the pump shaft -A-.

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The pump shaft is inserted after installing the new dual clutch.
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Lay the shaft down until then.
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Install the dual clutch. Refer to
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1.4 DSG Clutch, Installing, page 21 .
Prote AG.
1.4 DSG Clutch, Installing

Clutch Retaining Bar - T10303-
Dial Gauge Holder - VW387-
Dial Gauge - 0-10mm - VAS6079-
Caution


Circlip - DSG Clutch and Circlip
Circlip
1. Clutch 21
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
rier with both thumbs during the following steps.
The drive plate must be engaged between the teeth of the
exterior clutch pack.
If the drive plate is loosened, the clutch discs in the
DSG clutch can slip out of place and the DSG clutch
may not be correctly set during installation under certain
circumstances.
Installing
Caution
A used clutch must not be installed again.
Take the DSG clutch out of the packaging by pressing the

drive plate into the outer clutch pack carrier with both thumbs.
AG. Volkswagen AG d
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Check the bottom side of the multi-plate clutch to see if the 4
ce
le
un
pt
hub sealing rings are seated correctly and engage them in one
an
d
itte
another if necessary.
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The ends of the rings should not stand over one another.
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Turn the rings one time. They must move freely and must not
h re
hole
stick.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
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Prote AG.

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.
If no marking is available:
Mark the location of the tab to the outer clutch pack carrier
circumference with a waterproof marker as shown in the illus
tration.
When installing, the drive plate tab must be placed back on
this marked location.
Insert the Clutch Retaining Bar - T10303- in the positions on

the clutch cover as shown in the illustration.
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Set the DSG clutch using rotating and hub movements into an
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the clutch housing, but do not let it fall in. Press the drive plate ab
ility
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into the outer clutch pack carrier with both thumbs in the di wit
rection of -arrows- to install.
, is n
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spec
es, in part or in w
t to the co
rrectness of i
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ercia
A second technician should hold the Clutch Retaining Bar -

m
at
T10303- .
om
ion
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ate
Note
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The bolt remains installed until clutch end plate is installed.

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The DSG clutch must not be turned any more now, otherwise
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the Clutch Retaining Bar - T10303- could be twisted in its po
p by
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cted AG.
agen
1. Clutch 23
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.
Move the drive plate to the side.
Caution
Do not remove or lift the inner clutch pack carrier, under any
circumstances. The clutch discs could rotate themselves.
Identify the Circlip for the DSG Clutch

Select the 2 mm thick ring from the circlips delivered and install
it -arrow-.
Note
This circlip is temporary installed for the measurement of the axial

play.
First Measurement: n AG. Volkswagen AG do

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The Clutch Retaining Bar - T10303- remainsd binstalled.
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Install the Dial Gauge Holder - VW387-uthon the transmission
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Place the -dial gauge button- on input shaft.
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Adjust the -dial gauge- pretension to 0.
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Raise the dual clutch up as far as the stop and note the meas
h re
urement result.
hole
Second Measurement: spec

es, in part or in w
t to the co
The Clutch Retaining Bar - T10303- remains installed.
rrectness of i
l purpos
nform
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at
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ion
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or
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ate
do
priv
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for
en
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Prote AG.

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.
Adjust the -dial gauge- pretension again to 0.
Raise the clutch up as far as the stop again and note this
measurement as well
Now the Calculation Will Be Made to Determine Which of the Re
maining Nine Circlips Will Be Finally Installed:
The new circlip will be determined according to the following for
mula:
2nd Measured value 1st Measured value + 1.85 mm = thick
ness of circlip to be installed . Volkswage n AG n AG d
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Write down the result. Volks not
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The remaining nine circlips are staggered in h0.1
oris mm increments. nte
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Measure all the circlips and determiness the one that is the c
closes match to the result
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Determined Measurement for New Circlip
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ab
the New Circlip
ility
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2.27 mm 2.3 mm
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2.24 mm 2.2 mm
spec
t to the co
Remove the 2 mm circlip and replace it with the circlip that was
measured.
rrectne
Dispose of all other rings remaining and the 2 millimeter thick
ring.
ss o
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Note
nform
mer
atio
Circlips must only be installed one time.
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Insert the pump shaft. Cop py
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Note
agen
Prote AG.
The pump shaft must be slightly lifted and rotated in direction of

-arrow- in order for it to completely slide into the splines.
1. Clutch 25
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Direct Shift Gearbox
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Insert the drive plate into the DSG clutch.
ss c
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du
The protruding tab of the drive plate must be positioned be
an
itte
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tween the color-marked teeth of the outer clutch pack carrier.
erm
ab
Make note of markings that have been changed retrospec
ility
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tively.
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hole
spec
Caution
es, in part or in w
t to the co
Only the circlip removed beforehand from the new clutch
may be installed. Never install a used circlip.
rrectness of i
l purpos
nf
ercia
orm
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atio
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or c
thi
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Install the new drive plate circlip.
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The circlip must be installed so that the tab of the drive plate
Co
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-arrow- and the color-marked teeth of the outer clutch pack
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carrier are positioned between both ends of the circlip. py by
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The circlip must be completely engaged. Prote AG.
Check the exact installation position of the circlip and that the
circlip is engaged using a screwdriver.
Now remove the Clutch Retaining Bar - T10303- between the
DSG clutch and the housing.
Install the clutch end cover. Refer to
1.2 Clutch End Cover, Removing and Installing, page 15 .

2 Special Tools
Clutch Cover Plate Guide Sleeve - T10302-
Clutch Retaining Bar - T10303-
Dial Gauge - 0-10mm g-eVAS6079-

n AG. Volkswagen AG d
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es, in part or in w
t to the co
Dial Gauge Holder - VW387-

rrectness of i
l purpos
nform
mercia
at
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ion
c
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or
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ate
do
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for
en
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Cop py
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Prote AG.
2. Special Tools 27
34 Controls, Housing
1 Mechatronic
1.1 Overview - Mechatronic, page 28
1.2 Mechatronic, Removing and Installing, page 30
1.1 Overview - Mechatronic
1 - Transmission Fluid Drain

and Check Plug
45 Nm
There is an overflow
pipe with a 8 mm inner
hex behind this bolt
-item 3-
Item 3 (page 28)
Drain the transmission
fluid via the drain- and
check plug and re
moved overflow pipe AG. Volkswagen AG d
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2 - Seal d by Vo gu
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3 - Overflow Pipe ss c
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3 Nm
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Plastic
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To drain the transmis

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sion fluid, remove the

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drain and check plugs.

ole,
Refer to -item 1-
spec
Item 1 (page 28) , and

t to the co
remove the overflow

pipe.
The length of the over
rrectne
flow pipe determines the

fluid level inside the
s
transmission
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Allocate according to
inform
the Parts Catalog.

mer
atio
4 - Bolt
om
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c

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Quantity: 10
iv
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Tightening specification
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and sequence. Refer to

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Fig. Tightening Specification and Sequence for DSG Transmission Mechatronic -J743- ,
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5 - Transmission Cover Prote
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Removing and installing. Refer to 1.2 Mechatronic, Removing and Installing, page 30 .
6 - Bolt
Quantity: 5
Tightening specification and sequence. Refer to
Fig. Tightening Specification and Sequence for DSG Transmission Mechatronic -J743- ,
page 30
28 Rep. Gr.34 - Controls, Housing

7 - Seal
n AG . Volkswage
8 - DSG Transmission wageMechatronic - J743-
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Withuth O-rings on connector
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Removing and installing. Refer to 1.2 Mechatronic,
ss c
Removing and Installing, page 30 .
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nl
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9 - Bleed Cap
du
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Placed on bleed pipe
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ility
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10 - Bleed Pipe
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spec
Pressed into transmission
es, in part or in w
t to the co
11 - Transmission Fluid Pump
Insert with new seal
rrectness of i
Removing and installing. Refer to
8.2 Transmission Fluid Pump, Removing and Installing, page 107 .
l purpos
12 - Transmission Fluid Pump Cover

nform
ercia
With seal
m
at
om
i
Removing and installing. Refer to on
c

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or
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ate
13 - Bolt
do
priv
cum
or

f
en
ng
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Quantity: 4
Co
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Fig. Tightening Specification and Sequence of the Transmission Fluid Pump Cover -A-. ,
cop Vo
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cted
page 30
agen
Prote AG.
14 - Bolt
Quantity: 4
Different versions. For the correct allocation. Refer to the Parts Catalog.
There are different bolts for the transmission fluid pump. Refer to page 109
15 - Seal
Tightening specification and tightening sequence of the trans

mission cover -A-.
Tighten the bolts -arrows- diagonally in steps to 16 Nm.
1. Mechatronic 29
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:

Step Bolts Tightening Specification/Additional
Turn
1. -1 to 10- 5 Nm
2. -1 to 10- Tighten 90 further.
Tightening Specification and Sequence of the Transmission Fluid

Pump Cover -A-.
Tighten the bolts -arrows- diagonally in steps to 8 Nm.
AG. Volkswagen AG d
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1.2 Mechatronic, Removing and Installing
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1.2.1 DSG Transmission Mechatronic
aut
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Installing, Transmission Installed,
ss page 30 . c
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1.2.2 DSG Transmission Mechatronic J743 , Removing and

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Installing, Transmission Removed, page 39 .

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1.2.1 DSG Transmission Mechatronic -

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J743- , Removing and Installing, Trans

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spec
mission Installed
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Torque Wrench 5-50Nm - VAG1331-
rrectne
Used Oil Collection and Extraction Unit - SMN372500-

s
Oil Filler - VAS6262A-

s o
cial p
f inform
Caution
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atio
om

c
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or

thi
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Cop py
Bolts - DSG Transmission Mechatronic - J743 ht. rig
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Bolts - Pendulum Support Bolts to Transmission
by lksw
cted agen
Prote AG.

Bolts - Transmission Fluid Pan

Bolts - Transmission Fluid Pump Cover
O-rings - DSG Transmission Mechatronic - J743
Seal - Transmission Fluid Drain and Check Plug
Seal - Transmission Fluid Pan
Note
Follow the guidelines for clean working conditions. Refer to

Pay attention to the general repair information. Refer to
Removing
Always make sure that no dirt enters an open transmission.
Dirt entering can cause a transmission malfunction especially with
open Direct Shift Gearbox (DSG) Mechatronic and/or trans
mission fluid pump.
The Mechatronic can get stuck on the alignment pins when the
transmission is very warm. Let the transmission cold down.
Move the selector lever into P. AG. Volkswagen AG d
agen oes
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Remove the noise insulation. Refer to Body Exterior;byRep. Vol not
gu
ara
Gr. 66 ; Noise Insulation; Overview - Noise Insulationrise .
d
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If present: ss au ra
c
ce
le
Remove the connecting hose between the charge air cooler

un
pt
an
and the charge air pipe. Refer to Rep. Gr. 21 ; Overview -
d
itte
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Charge Air System .
rm
ab
pe
ility
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Note
hole
spec
es, in part or in w
It is possible that parts, which have nothing to do with the Me
t to the co
chatronic unit, will have to be removed. It depends on the vehicle
equipment. Make sure there is enough room around the Mecha
tronic unit.
rrectness of i
l purpos
Depending on the vehicle, the parts could be:

nform
ercia
Fan mount -arrow-

m
a
com
tio
Charge or cold air pipes

n in
r
te o
thi
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iva
do
Caution
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rp
cum
fo
en
ng
t.
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Risk of destroying Mechatronic with static discharge.
Co
Cop py
t. rig
gh
Do not touch contacts in the Mechatronic connector with
ht
pyri by
Vo
hands.
co lksw
by
cted agen
Prote AG.
To discharge any static electricity, touch the vehicle ground

with hand (without wearing a glove). Refer to page 7 .
1. Mechatronic 31
Direct Shift Gearbox - Edition 09.2015 AG. Volkswagen AG d
agen oes
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Release and remove the connector rotary lock -1- for the d bMe ara
ise nte
chatronic by turning it in the direction of the starter t-A-.
ho
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un
pt
an
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itte
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rm
ab
pe
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
Remove the wires and bracket from the front of the transmis
sion cover -arrows- (two M6 nuts).
l purpos
Route the wires near the transmission cover upward and tie
them up.
nform
ercia
Place the Used Oil Collection and Extraction Unit -

m
a
SMN372500- under the transmission near the transmission
com
tion in
cover.
r
te o
thi
s
iva
do
r
Caution
rp
cum
fo
en
ng
t.
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Fluid will leak out of the transmission cover when the bolts are
Co
Cop py
removed. Risk of injury due to hot transmission fluid.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Loosen the bolts -arrows- on the transmission cover -A- diag

onally and then remove them. Hold down the transmission
cover at the same time.
Drain the transmission fluid and remove the cover and seal.
Approximately 3 liters (3.1 quarts) of transmission fluid will drain
out.
Note
Always replace the screws on the transmission fluid pan.

page 110 .
Remove the lower left front wheel housing liner. Refer to
Body Exterior; Rep. Gr. 66 ; Wheel Housing Liner; Overview
- Front Wheel Housing Liner .
Remove the bolts -arrows- from the transmission fluid pump

cover and remove the cover -A-.
Note
Always replace the cover and the transmission fluid pump bolts.

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 n AG. Volkswagen AG do
tronic. olks
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ab
ility
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Loosen and remove the bolts -1 through 10- in the specified
h re
sequence.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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t.
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Cop py
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cted agen
Push the transmission rearward and pull the Mechatronic
Prote AG.
carefully from the transmission housing until the sensor arm

-B- on the rear is no longer in the transmission housing.
When handling the Mechatronic, be particularly aware of the
long sensor arm -B-.
Carefully move the DSG Transmission Mechatronic - J743-
downward.
Store Mechatronic Properly
1. Mechatronic 33
AG. Volkswagen AG d
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Caution
ab
ility
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Never lift the Mechatronic by the sensor arm and never let it
h re
rest on the arm.
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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fo
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Prote AG.

If the arm is damaged, the Mechatronic must be replaced.

Installing
Touch a grounded object before touching the Mechatronic
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page 7 . swa
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Note tho eo
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The DSG Transmission Mechatronic - J743- and the transmission
nl
pt
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must be the same temperature. Otherwise the alignment pins will
an
itte
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not clamp during installation.
erm
ab
ility
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hole
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es, in part or in w
t to the co
rrectness of i
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Carefully mount the Mechatronic onto the alignment pins

-arrow-. The goal is for the sensor arm to be in its
-installed position-.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
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cted agen
Prote AG.
1. Mechatronic 35
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.
Tighten the bolts -1 to 10- in the tightening sequence provided.
Tightening specification. Refer to :
Fig. Tightening Specification and Sequence for DSG
Transmission Mechatronic -J743- , page 30
Replace both -O-rings- if the old Mechatronic is being instal

led again.
Coat the O-rings with DSG transmission fluid.
A new Mechatronic already has new O-rings.
Replace the transmission cover gasket.
Make sure the seal fits correctly.
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ole,
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t to the co
Place the transmission fluid pan -A- over the Mechatronic. Be

careful not to pinch any wires when doing this.
Install the new bolts -arrows- and tighten in a diagonal se
rrectne
quence in stages.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
r
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

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.
Install the lower left front wheel housing liner. Refer to Body
Exterior; Rep. Gr. 66 ; Wheel Housing Liner; Overview - Front n AG. Volkswagen AG do
Wheel Housing Liner . olks
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un
pt
an
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itte
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erm
ab
ility
ot p
Connect the connector -A- on the DSG Transmission Mechatronic
wit
is n
h re
- J743- as follows:
ole,
spec
The arrow -D- on the DSG Transmission Mechatronic - J743-

-B- must line up with the connector -A- as well as with the tab
t to the co
-C-.
Connect the connector -A- carefully all the way and then turn
rrectne
the lock clockwise in direction of -arrow-.
ss o
cial p
f inform
mer
atio
om
n
c
i
Install the new bolts -1- for the pendulum support on the trans
or
n thi
e
mission. Refer to Rep. Gr. 10 ; Subframe Mount; Overview

t
sd
va
- Subframe Mount .
i
o
pr
cum
r
fo
en
ng
Install the air filter housing if it was removed earlier. Refer to

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Engine Mechanical, Fuel Injection and Ignition; Rep. Gr. Cop py
t. rig
24 ; Air Filter; Air Filter Housing, Removing and Installing . opyri
gh by
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Do not start the engine. Prote
cted AG.
agen
Move the Used Oil Collection and Extraction Unit -

SNM372500- under the transmission near the transmission
fluid drain and check plug.
1. Mechatronic 37
Remove the transmission fluid drain- and check plug -arrow-.
Install the Oil Filler - VAS6262A- into the check hole hand-
tight.
AG. Volkswagen AG d
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un
pt
Shake before opening.

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rm
ab
Attach the Oil Filler - VAS6262A- to the oil bottle. Be sure to

pe
ility
read the instructions. Refer to page 113 .

ot
wit
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h re
Fill 3 liters (3.1 quarts) of transmission fluid.

hole
spec
To change containers, close the shut-off valve or hold the Oil

es, in part or in w
t to the co
Filler - VAS6262A- higher than the transmission.

Start the engine and check the fluid level. Refer to
9.1 Transmission Fluid Level, Checking, page 113 . The Oil
rrectness of i
Filler - VAS6262A- remains installed.

l purpos
Install the noise insulation. Refer to Body Exterior; Rep. Gr.

66 ; Noise Insulation; Overview - Noise Insulation .
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Connect the Vehicle Diagnostic Tester .

Perform a basic setting on the DSG Transmission Mechatronic
- J743- .
Note
After installing a new Mechatronic, readapt the immobilizer.
Tightening Specifications
Refer to 1.1 Overview - Mechatronic, page 28 .
Cable bracket on the transmission cover. Refer to
3.3 Transmission Tightening Specifications, page 96 .
1.2.2 DSG Transmission Mechatronic -

J743- , Removing and Installing, Trans
mission Removed
Caution
AG. Volkswagen AG d
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This procedure contains mandatoryd replaceable
by
Vo parts. Refer gu
ara
to component overview prior to starting
orise procedure. nte
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Bolts - DSG Transmission Mechatronic - J743
erm
ab
ility
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Bolts - Pendulum Support Bolts to Transmission

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Bolts - Transmission Fluid Pan

hole
spec
Bolts - Transmission Fluid Pump Cover

es, in part or in w
t to the co
O-rings - DSG Transmission Mechatronic - J743

Seal - Transmission Fluid Drain and Check Plug
rrectness of i
Seal - Transmission Fluid Pan

l purpos
nf
Note
ercia
orm
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Follow the guidelines for clean working conditions. Refer to

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Pay attention to the general repair information. Refer to

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Always make sure that no dirt enters an open transmission. Dirt Cop py
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entering can cause a transmission malfunction especially with
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open Direct Shift Gearbox (DSG) Mechatronic and/or oil pump.
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Prote AG.
Removing
SMN372500- or Drip Tray under the transmission.
1. Mechatronic 39
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). Its length deter
mines the oil level in the transmission.
Remove this overflow pipe and drain the rest of the transmis
sion fluid.
Note
Approximately 5 liters (5.28 qts) of transmission fluid will drain.

Continue to have the Used Oil Collection and Extraction Unit -
SMN372500- or Drip Tray under the G transmission.
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Install the overflow epiped by and tighten. ua
ran
oris tee
If necessary change
auth the transmission fluid filter. Refer to or
ac
8.3 Transmission
ss Fluid Filter, Removing and Installing,
ce
page 110 .
le
un
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Loosen transmission fluid pan bolts -arrows- diagonally and
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ab
pe
ility
remove. Remove the transmission fluid pan.
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spec
Note
es, in part or in w
Always replace the screws on the transmission cover. t to the co

rrectness of i
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Remove the bolts -arrows- from the transmission fluid pump

a
com
tio
cover and remove the cover -A-.

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Note
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Always replace the bolts for the transmission fluid pump cover
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Touch a grounded object again before touching the Mecha
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Prote AG.
tronic.
Remove the bolts -1 through 10- diagonally. Start with the bolt
-1-.

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Replace all 10 -bolts-.

Remove the Mechatronic.
When handling the Mechatronic, be particularly aware of the
long sensor arm.
Store Mechatronic Properly
1. Mechatronic 41
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Caution
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Never lift the Mechatronic by the sensor arm and never let it
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rest on the arm.

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If the Arm is Damaged, the Mechatronic Must Be Replaced.

Installing
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rrectness of i
Replace both O-rings -arrows- on the Mechatronic connection
l purpos
if the old Mechatronic is going to be installed again.

A new Mechatronic already has new rings.
nform
ercia
Coat the O-rings with DSG transmission fluid.

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Carefully mount the Mechatronic on the alignment pin

-arrow-. The goal is for the sensor arm to be in its
-installed position-.
1. Mechatronic 43
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The sensor arm must not touch the sensor wheel.

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All of the bolts -1 through 10- must be replaced.

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ab
ility
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es, in part or in w
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First install all of the bolts -1 to 10- and tighten them by hand. t. C rig
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Tighten all of the bolts -1 to 10- in the tightening sequence
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provided. Tightening specification. Refer to Prote AG.
Fig. Tightening Specification and Sequence for DSG
Transmission Mechatronic -J743- , page 30
Clean the transmission fluid pan gasket and transmission
sealing surfaces.
Make sure the seal fits correctly.
Place the transmission cover -A- over the Mechatronic. Be
careful not to pinch any wires when doing this.
Install the new bolts -arrows- and tighten in a diagonal se
quence in stages.
1. Mechatronic 45
Mount the new transmission fluid pump cover -A-. Tighten the
stages.
After Installing Transmission
Fill with transmission fluid. Refer to
9 Transmission Fluid, page 113 .
Connect the Vehicle Diagnostic Tester Vehicle Diagnostic

Tester .
Perform a basic setting on the DSG Transmission Mechatronic
- J743- .
Note
After installing a new Mechatronic, readapt the immobilizer.
Refer to 1.1 Overview - Mechatronic, page 28 .
AG. Volkswagen AG d
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2 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
2.4 Button in Handle, Moving Into Installation Position,
page 53
2.5 Selector Mechanism, Removing and Installing,
page 55
2.6 Selector Lever Cable, Removing and Installing,
page 63
2.7 Gearshift Mechanism, Checking, page 67
2.8 Selector Lever Cable, Checking and Adjusting,
page 68
2.9 Selector Shaft Seal, Replacing, page 69
2.1 Overview - Selector Mechanism

2.1.1 Overview - Selector Mechanism, ZF, page 47 .
2.1.2 Overview - Selector Mechanism, ECS, page 49 .
2.1.1 Overview - Selector Mechanism, ZF
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c
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2. Selector Mechanism 47
1 - Handle with Shift Cover

Do not remove the han
dle unnecessarily. For
emergency release, on
ly cover must be re
moved. Refer to agen
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2.2.1 Emergency Re olksw not
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page 50 . ut
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Removing and instal ss c
ling. Refer to
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2.3 Selector Lever
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Handle, Removing and
erm
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Installing, page 51 .
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2 - Selector Mechanism is n
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With integrated Selector
spec
Lever Sensor System
t to the co
Control Module - J587-
with Selector Lever -
E313- , Tiptronic Switch
- F189- , Selector Lever
rrectne
Park Position Lock
Switch - F319- and Shift
ss
o
cial p
f i
Removing and instal
nform
ling. Refer to
mer
atio
2.5 Selector Mecha
om
n
c
i
or
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stalling, page 55 .
thi
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3 - Bolt
i
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8 Nm
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4 - Plugs
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5 - Nut with Collar
Prote AG.
8 Nm
Quantity: 4
6 - Selector Housing
Available only together with the selector mechanism. Refer to the Parts Catalog
7 - Transmission
8 - Bolt
20 Nm + 90
Quantity: 2
For attaching the cable bracket to the transmission
9 - Lock Washer
10 - Lock Washer
Installed location: the offset side faces forward, toward the front of the vehicle.
11 - Lock Washer
12 - Selector Lever Cable
Do not grease the selector lever cable.

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 .
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2.1.2 Overview - Selector Mechanism, ECS ho
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1 - Handle with Shift Cover

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Do not remove the han
itte
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erm
dle unnecessarily. For
ab
ility
emergency release, on
ot p
wit
ly cover must be re
, is n
h re
moved. Refer to
hole
spec
2.2.2 Emergency Re
es, in part or in w
lease from P, ECS,
t to the co
page 51 .
Removing and instal
ling. Refer to
rrectness of i
2.3 Selector Lever
l purpos
Handle, Removing and

Installing, page 51 .
nform
ercia
2 - Bolt
8 Nm
m
at
om
io
Quantity: 4
n
c
in t
or
his
e
3 - Selector Mechanism
at
do
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With integrated Selector

p
cum
or
Lever Sensor System

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Control Module - J587-
Co
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with Selector Lever -
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E313- , Tiptronic Switch p by
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- F189- , Selector Lever
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Park Position Lock
AG.
Switch - F319- and Shift

Removing and instal
ling. Refer to
2.5 Selector Mecha
stalling, page 55 .
4 - Selector Lever Cable
Do not grease the selec
tor lever cable.
Removing and instal
ling. Refer to 2.6.2 Selector Lever Cable, Removing and Installing, ECS, page 65 .
Checking. Refer to 2.8 Selector Lever Cable, Checking and Adjusting, page 68 .
Adjusting. Refer to 2.8 Selector Lever Cable, Checking and Adjusting, page 68 .
5 - Lock Washer
6 - Nut with Collar
8 Nm
Quantity: 4
7 - Selector Housing
Available only together with the selector mechanism. Refer to the Parts Catalog
8 - Cover
9 - Bolt
20 Nm + 90
Quantity: 2
For attaching the cable bracket to the transmission
10 - Transmission
11 - Lock Washer
Replace after removing AG. Volkswagen AG d
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Installed location: the offset
ed side
by
V
faces forward, toward the frontgu of the vehicle.
ara
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12 - Bolt au
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13 Nm s
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un
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Selector lever cable adjusting screw
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13 - Lock Washer
erm
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ility
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spec
2.2 Emergency Release from P
t to the co
2.2.1 Emergency Release from P, ZF, page 50 .
rrectne
2.2.2 Emergency Release from P, ECS, page 51 .
2.2.1 Emergency Release from P, ZF
ss o
cial p
f
Do Not Remove the Handle
inform
mer
Press the brake or set the parking brake.

atio
om
Open the storage compartment door.

n
c
i
or
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Grab and under the shift cover by hand and by pulling upward
t
sd
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unclip the cover.

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Prote AG.

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.
Note
If the selector lever is not moved back into P, the solenoid for
the shift block will be automatically locked in the position P. The
solenoid must be released again.
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2.2.2 Emergency Release from P, ECS
ole,
spec
Do Not Remove the Handle
t to the co
Press the brake or set the parking brake.
Grab and under the shift cover by hand and pulling upward rrectnes
unclip the cover.
s o
cial p
f i
Unclip the shift cover and hold it to the side.

nform
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With a screwdriver push the plastic part on the side from the
right and hold it in this position
The selector lever can now be moved out of P.
Note
If the selector lever is not moved back into P, the solenoid for
the shift block will be automatically locked in the position P. The
solenoid must be released again.
2.3 Selector Lever Handle, Removing and

Installing
Hose Clip Pliers - VAG1275A-
Caution

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Mandatory Replacement Parts auth or
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Clamp - Shift Handle
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Short Description:
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The handle is removed together with the shift cover.
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Removing
h re
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spec
Move the selector lever into D. es, in part or in w
t to the co
It is not necessary to pull out the button -arrow- manually. The
push button locks in the installation position by itself when the
handle is removed.
rrectness of i
l purpos
Grab and under the shift cover by hand and pulling upward
unclip the cover.
nform
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at
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c
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Disconnect the connector.
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Cut the clamp under the boot -arrow- with a side cutter.
Pull the handle up without pressing the button.
Note
Do not push the button once the handle has been removed oth
erwise it will not be possible to remove the handle again.
Installing
Install in reverse order of removal. Note the following:
The selector lever is in the D position.

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Note
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There is the possibility that the button can be pressed into the
agen
Prote AG.
handle. Never install the handle when the button is pressed in.
Move the button in the installation position. Refer to
page 53 .
A new handle is delivered with an assembly fastener. Pull out
the safety catch in direction of -arrow- just before installing the
new handle.
Install the handle with a new clamp -arrow-. Do not clamp the
clamp yet.
Press the button after installing it.
Note
If the button stays in the handle after being pressed, this means
it was installed incorrectly. If this happens, remove the handle
again and move the button in the installation position again. Refer
to
page 53 . Install the handle again.
If the button after being pressed return to its starting position,

the clamp can be clamp off using Hose Clamp Pliers -
VAG1275A- .
Connect the connector.
Clip on the cover.
2.4 Button in Handle, Moving Into Installa

tion Position
If the button was pushed in by mistake, the installed position can
be set again.
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
lation Position:
Make sure the assembly fastener has an eye -arrow- at the front.
Other assembly fasteners cannot be used.
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Press the button and push the assembly fastener
s au(with the ra
c
eye) -arrow- all the way in until it latches into place. Then re s
ce
e
nl
lease the button. The button locks into the installation position
pt
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when the assembly fastener is pulled out.
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Moving the Handle without an Assembly Fastener into the In
ility
ot p
stallation Position:
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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Remove the trim -A- from the handle.
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mercia
at
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c
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do
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Prote AG.

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
-II- the button is in the installation position
Note
Push the lever into the groove and no further.

Install the trim back onto the selector mechanism only after the
handle is installed. This way it is possible to see if the small
lever fits into the pull rod when the button is pushed.
2.5 Selector Mechanism, Removing and In

stalling
2.5.1 Shift Mechanism with Selector Lever Cable, Removing
and Installing, page 55
2.5.2 Gearshift Mechanism without Selector Lever Cable, Re
moving and Installing, ZF, page 57
2.5.3 Shift Lever Mechanism without Selector Lever Cable,
Removing and Installing, ECS, page 60
2.5.1 Shift Mechanism with Selector Lever

Cable, Removing and Installing
Short Description
Remove the center console inside the passenger compartment.
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It is necessary to remove the heat
y V shield under the vehicle.
olks not
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b ara
ed
Removing thoris nte
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Remove the Refer to selector
ss lever handle. c
ce
2.3 Selector Lever Handle, Removing and Installing, page

le
un
pt
51 .
an
d
itte
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ab
Remove the center console. Refer to Body Interior; Rep.

pe
ility
Gr. 68 ; Center Console; Center Console, Removing and In

ot
wit
, is n
stalling .
h re
hole
Remove the air guide channel from the center console. Refer
spec
es, in part or in w
to Heating, Ventilation and Air Conditioning; Rep. Gr. 87 ;

t to the co
Air Routing; Overview - Air Routing and Air Distribution in Pas

senger Compartment .
Remove left and right bolts -1- and bracket -2-.
rrectness of i
Disconnect the connector from the selector mechanism to the

l purpos
vehicle wiring harness.

Remove the air filter housing:
nform
mercia
Gasoline engine. Refer to Engine Mechanical, Fuel Injec

a
com
ti
tion and Ignition; Rep. Gr. 24 ; Air Filter; Air Filter Housing,
on in
Removing and Installing .

r
te o
thi
s
iva
do
Diesel engine. Refer to Rep. Gr. 23 ; Air Filter; Air Filter

r
rp
cum
Housing, Removing and Installing .

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ng
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Prote AG.
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. Otherwise the selector lever cable could get dam
aged.
Remove the center tunnel heat shield under the gearshift
mechanism. Refer to Body Exterior; Rep. Gr. 66 ; Molding/
Trim/Extensions/Trim Panels; Floor Heat Shield, Removing
and Installing .
Remove the bracket -A-, if equipped.

Remove the nuts -arrows- in the vehicle interior.
Remove the selector mechanism -B- with the selector lever
cable and selector housing downward.
Installing
Note
Do not bend or kink the selector lever cable.

Do not lubricate the selector lever cable.
After installation, the selector lever cable movement must be
checked and adjusted.
Install the heat shield under the gearshift mechanism. Refer

to Body Exterior; Rep. Gr. 66 ; Molding/Trim/Extensions/ n AG. Volkswagen AG do
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Trim Panels; Floor Heat Shield, Removing and Installing
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ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Prote AG.

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
Heating, Ventilation and Air Conditioning; Rep. Gr. 87 ; Air
Routing; Overview - Air Routing and Air Distribution in Pas
Install the center console. Refer to Body Interior; Rep. Gr.
68 ; Center Console; Center Console, Removing and Instal
ling .
Install the selector lever handle. Refer to
51 .
Adjust the selector lever cable. Refer to
page 68 .
Check the selector mechanism. Refer to
2.7 Gearshift Mechanism, Checking, page 67 .
Install the air filter housing:
Selector mechanism to the body. Refer to
2.1 Overview - Selector Mechanism, page 47 .
2.5.2 Gearshift Mechanism without Selector

Lever Cable, Removing andAGInstalling,
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Short Description
rrectness of i
It is necessary to remove the heat shield under the vehicle.

l purpos
Removing
Remove the selector lever handle. Refer to
nf
ercia

orm
51 .
m
atio
om

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Remove the bracket -2-, to do this remove the left and right
bolts -1-.
vehicle wiring harness. n AG. Volkswagen A ge G do
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Position the selector lever on the selectorbymechanism
Vol
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in the ot g
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N position. The cable can only be loosened
ris
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Remove the center tunnel heat shield
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Remove the plugs, and remove the lock washer -arrow-.
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atio
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Insert a large screwdriver into the grooves on the locking

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mechanism and turn 90 in the direction of the -arrow-.
pr
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Remove the cable from the selector mechanism.

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Remove the selector mechanism -B- with the gearshift hous
ing downward.
Installing
Note

The selector lever for the gearshift mechanism is in the N

position. The cable can only be locked in this position.

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.
The cable is correctly locked when the grooves on the locking

mechanism are at a right angle to the cable.
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Install new lock washer -arrow- and replace the plugs. h re

hole
spec
es, in part or in w
Install the heat shield under the shift lever mechanism. Refer
t to the co
to Body Exterior; Rep. Gr. 66 ; Molding/Trim/Extensions/

Trim Panels; Floor Heat Shield, Removing and Installing .
rrectness of i
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page 68 . n AG. Volkswagen AG do
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Check the selector mechanism. Refer to byV
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2.5.3 Shift Lever Mechanism without Selector
wit
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Lever Cable, Removing and Installing,
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ECS
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Caution
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Lock Washer - Selector Housing

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Cover - Selector Housing
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Short Description
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It is necessary to remove the heat shield under the vehicle.
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Removing
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Remove the selector lever handle. Refer to
51 .
stalling .

Remove the bracket -2-, to do this remove the left and right
bolts -1-.
vehicle wiring harness.
Position the selector lever on the V
selector mechanism in the
. olkswagen AG
N position. swa
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Remove the center d btunnel heat shield under the gearshift
ua
ran
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mechanism. Referthor to Body Exterior; Rep. Gr. 66 ; Molding/
tee
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Trim/Extensions/Trim
ss
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Panels; Floor Heat Shield, Removing r ac
and Installing .
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Pry up the lower cover from the selector mechanism in the
ot p
direction of -arrow- and remove.
wit
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Note
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Do not reuse the cover. Always replace after removing.
rrectness of i
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Release the cable as shown with a screwdriver and remove

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from the selector lever in the direction of -arrows-.

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Remove the lock washer in the direction of -arrow-.

Remove the cable from the selector mechanism.
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Remove the selector mechanism -B- with the gearshift hous ot p
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Note
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ss o
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mer
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The selector mechanism selector lever is in the N position.

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Guide the cable on the selector mechanism, inset in the se
um
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lector lever and install new lock washer.
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Install the heat shield under the gearshift mechanism. Refer t. C rig
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to Body Exterior; Rep. Gr. 66 ; Molding/Trim/Extensions/ yri
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ling .
51 .
page 68 .

2.6 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 Selector Lever Cable, Removing and In

stalling, ZF
Caution


Lock Washers - Selector Lever Cable
Removing
Remove the air filter housing. Refer to Engine Mechanical,
Fuel Injection and Ignition; Rep. Gr. 24 ; Air Filter; Air Filter
Housing, Removing and Installing or Rep. Gr. 23 ; Air Filter;
Air Filter Housing, Removing and Installing
Use pliers to remove the lock washer -B-. Do not use a sharp-
edged lever. Otherwise the selector lever cable could get dam
aged.
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Position the selector lever on the selector mechanism inagthe
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N position. The cable can only be loosened indthis gu
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Remove the center tunnel heat shield underut
ho the gearshift eo
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mechanism. Refer to Body Exterior; Rep.
ss a Gr. 66 ; Molding/ c
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un
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and Installing .
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Remove the plugs, and remove the lock washer -arrow-.

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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.
Installing
Note

After installing check the selector lever cable for ease of move
ment.
The selector lever for the gearshift mechanism is in the N

position. The cable can only be locked in this position. wage
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Guide the cable in the selector mechanism in direction o
ir seof
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-arrow- until the locking mechanism -arrow- is visible.
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Turn the locking mechanism 90 in the direction of the
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-arrow- with a large screwdriver.
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The cable is correctly locked when the grooves on the locking
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mechanism are at a right angle to the cable.

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Install newau ra
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Remove the cable from the transmission and secure using a
s o
new lock washer -B-. Do not install the lock washer -A- yet. It
cial p
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will be installed after the cable is checked and adjusted.
form
mer
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page 68 .
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2.7 Gearshift Mechanism, Checking, page 67 . copy Vo
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Install the air filter housing. Refer to Engine Mechanical,
AG.
Fuel Injection and Ignition; Rep. Gr. 24 ; Air Filter; Air Filter
Housing, Removing and Installing or Rep. Gr. 23 ; Air Filter;
Air Filter Housing, Removing and Installing
2.6.2 Selector Lever Cable, Removing and In

stalling, ECS
Caution


Lock Washers - Selector Lever Cable
Cover - Selector Mechanism
Removing

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Use pliers to remove the lock washer -B-. Do Vnot
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wa not
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Position the selector lever on the
ss selector mechanism in the c
N position. The cable can only be loosened in this position.
ce
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Remove the center tunnel heat shield under the gearshift
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and Installing .
h re
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Pry up the lower cover from the selector mechanism in the
es, in part or in w
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direction of -arrow- and remove.
rrectness of i
Note
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Do not reuse the cover. Always replace after removing.
nform
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Release the cable as shown with a screwdriver and remove
fo
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g
from the selector lever in the direction of -arrows-.

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t.
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Remove the lock washer in the direction of -arrow-.

Pull the cable from the selector mechanism and remove.
Installing
Note

The selector mechanism selector lever is in the N position.

Guide the cable on the selector mechanism, inset in the se
lector lever and install new lock washer.

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 68 .
2.7 Gearshift Mechanism, Checking

The starter does not work when the selector lever is in R, D
and S or in the tiptronic gate.
Over 5 km/h:
The shift lock solenoid must not block the selector lever when the
lever is in N. The selector lever can be moved back into a an
other gear. gen AG
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Below 5 km/h: byV gu
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The shift lock
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ss after the lever is moved into N. The selector lever c can
be moved out of N only when the brake pedal is pressed.
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Selector Lever in P and the Ignition Turned on

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If the brake pedal is not depressed:

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The selector lever is locked and cannot be moved out of P when

ole,
spec
the locking button is pressed. The shift lock solenoid blocks the
selector lever.
t to the co
If the brake pedal is depressed:

The shift lock solenoid releases the selector lever. It is possible
rrectne
to shift into a gear. Slowly move the selector lever slowly from P
through S; while doing this, check whether display of selector
s
lever position in instrument panel insert matches actual selector

s o
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lever position.
f inform
mer
The Selector Lever is in N and the Ignition is Turned On:

atio
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If the brake pedal is not depressed:

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If the brake pedal is depressed: . Cop py
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The shift lock solenoid releases the selector lever. It is possible
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to shift into a gear.
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Selector Level in the Tiptronic Position
Move selector lever into Tiptronic gate:
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.
Ignition and Lights Switched On
The appropriate symbol is being lit up in shift mechanism cover.
Transmission Range Display
Simultaneous lighting of all segments of transmission range se
lector lever display indicates transmission is in emergency run
ning mode.
2.8 Selector Lever Cable, Checking and Ad

justing
Short Description
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gen AG does
The selector lever cable must be disconnected from the trans Vol
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mission in order to check it for ease of movement. Lay the ed
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Then selector lever is moved and installed again on the trans
ss c
mission.
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After that, selector lever cable must be adjusted.
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Do not lubricate the cable connections.
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After that, the selector lever cable must be adjusted.
h re
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spec
Always Adjust the Selector Lever Cable If:
es, in part or in w
t to the co
The selector lever cable was removed from the transmission.
The engine and/or transmission were removed and installed.
rrectness of i
Parts of subframe mount were removed and installed.
l purpos
The cable itself or the selector mechanism was removed and

installed.
nform
ercia
Engine/transmission positions changes, for example, were in

m
stalled free of tension.

a
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Checking
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Move the selector lever into P.

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Gasoline engine. Refer to Engine Mechanical, Fuel Injec C py
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Remove the selector lever cable from the transmission.
Move the selector lever from P through S and back to P
several times.
The selector lever must move easily.
Adjust the selector lever cable.
Adjusting

Gearshift Lever, Moving into P

The transmission gearshift lever must be pushed all the way
back.
Pull the transmission gearshift lever forward.
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Push the transmission gearshift lever to the rear -arrow-.
t to the co
P is in the Second Detent.
rrectne
Note
s
Make sure the transmission is in P (parking lock is engaged)
s o
if raising the vehicle. It must not be possible to turn the front
cial p
f in
wheels.
form
mer
The transmission is also in P if the vehicle does not move
atio
m
with wheels spinning freely.

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Install the cable with the loose adjusting screw -arrow- and the
p
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new lock washer -A and B-, if they were removed earlier.

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Tap the handle on the selector lever back and forth gently but
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Tighten the adjusting screw -arrow-.
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This ends the adjustment.

Component Nm
Selector lever cable adjusting bolt 13
2.9 Selector Shaft Seal, Replacing

Short Description:
The seal can be replaced only when the transmission is removed.
Caution


Nut - Gearshift Lever

Press Piece - Shift Rod/Alternator - VW423-
Puller - Crankshaft/Power Steering Seal - T20143-
Sealing Grease - G 052 128 A1-
olkswagen AG
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Remove the transmission. olksRefer to
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3.1 Transmission,
ed
Removing,
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Remove the selector
au
tho lever cable from the transmission. Refer e or a
to ss c
2.5 Selector Mechanism, Removing and Installing,
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page 55 .
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Remove nut -arrow- and remove transmission gearshift lever
ility
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-A- from the gearshift shaft.
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rrectness of i
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atio
Pry out the seal in direction of -arrow-.

om
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or c
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Lightly oil the new gasket on the outer edge.

Fill the space between the sealing and dust lip -arrow- halfway
with Sealing Grease - G 052 128 A1- .

The closed side of the gasket -arrow- points to the Press Piece
- Shift Rod/Alternator - VW423- . gen AG
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Install the new seal all the way. Do not tilt the gasketdb
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t to the co
Position the gearshift lever -A- and tighten the new nut
-arrow-.
The Gearshift Lever Only Fits to the Splines in One Position.
rrectness of i
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Attach the selector lever cable to the transmission. Refer to
nform
ercia

m
page 68 .
a
com
tion in
r
te o
thi
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Transmission selector lever to selector shaft. Refer to
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c
6.1 Overview - Transmission, page 101 .
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Golf 2015 , Golf Variant 2015 tho tee
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Direct Shift Gearbox - Edition 09.2015 ss
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3 Transmission, Removing and Instal
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3.1 Transmission, Removing, page 72 .
hole
spec
es, in part or in w
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3.1 Transmission, Removing
rrectness of i
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3.1.1 Transmission, Removing, Vehicles with Gasoline En
gine, page 72
nform
ercia
3.1.2 Transmission, Removing, Vehicles with Turbo Diesel
Engine, page 81 m
a
com
tio
3.1.1 Transmission, Removing, Vehicles with
n in
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thi
Gasoline Engine
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Brief description
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The transmission is removed downward separately. t. Cop py
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From above: yri
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The battery, air filter and starter are removed. Engine and trans
agen
Prote AG.
mission are supported before the left subframe mount is removed.
From underneath:
The -subframe- is removed together with the
-pendulum support- and -both control arms-. The -steering gear-
remains in the vehicle.
Both driveshafts are disconnected from the transmission and re
main inside the wheel bearing housings. Occasionally they will be
moved to the side, but they still remain on the vehicle.

Engine Support Bridge - Gearbox Adapter - 10-222A/29-
Engine Support Bridge - Engine Support 18 - 10-222A/18-
Engine/Gearbox Support Shackle (2 pc.) - 10-222A/12- (quan
tity 2)
Transmission Support - Pins 29 - 3282/29-
Transmission Support - 3282-
Engine and Gearbox Jack - VAS6931-
Transmission Support - Mounting Plate 42A - 3282/42A-
Hose Clamps - Up To 25 mm - 3094-
Tensioning Strap - T10038-
Engine Bung Set - VAS6122-
Insert Tool - 18mm - T10179-
Socket - Xzn 14 - T10061-

Engine Support - Basic Set Square Pipe - T40091/1- (quantity

2)
Engine Support - Basic Set Movable Joint - T40091/3- (quan
tity 2)
Engine Support - Supplement Kit Spindle - T40093/3- (quan
tity 2) from the Engine Support - Supplement Kit - T40093A-
Engine Support Brackets - T40093/3-6- (quantity 2)
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Removing
es, in part or in w
t to the co
Lift the vehicle, all four mounts from lifting platform at the same
height.
rrectness of i
Remove the engine cover. Refer to Rep. Gr. 10 ; Engine
l purpos
Cover; Engine Cover, Removing and Installing .

Remove the air filter housing. Refer to Rep. Gr. 24 ; Air
nf
ercia
o
Filter; Air Filter Housing, Removing and Installing .
rm
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atio
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Cop py
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Remove the battery and the battery tray -1- -arrows-. Refer to
co Vo
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cted
Electrical Equipment; Rep. Gr. 27 ; Battery, Removing and
agen
Prote AG.
Installing .
3. Transmission, Removing and Installing 73

Remove the selector lever cable from

gen AG. Vothe transmission
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does
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-arrows-. y Volk not
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Note
rrectne
Use pliers to remove the lock washer from the cable bracket.
ss
Do not use a sharp-edged lever. Otherwise the selector lever
o
cial p
f
cable could get damaged.
inform
mer
Remove the cable bracket -2- from the transmission, if nec
atio
m
essary. Remove the bolts -1- and the lock washer -3-.
o
n
c
i
or
n
Replace the bolts -1- and the lock washers.
thi
te
sd
iva
o
r
Bolt tightening specification -1- 20 Nm +90.

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fo
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t.
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. rig
Caution
ht ht
rig by
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cted
Risk of damaging the selector lever cable.
agen
Prote AG.
Remove the selector level cable from the cable bracket

when lowering transmission.
Remove the charge air pipe. Refer to Rep. Gr. 21 ; Over

view - Charge Air System .
Place a lint-free cloth on to transmission fluid cooler and trans
mission to absorb escaping coolant.
WARNING
Risk of scalding due to hot steam and hot coolant.

The cooling system is under pressure when the engine is
warm.
Reduce the pressure by covering the coolant reservoir cap
with cloths and carefully opening.

Clamp the coolant hose with the Hose Clamps - Up To 25mm

- 3094- .
Loosen the hose clamps -arrows- and remove the coolant ho
ses from the transmission fluid cooler.
Remove the bolts -1- and move the Transmission Coolant
Valve - N488- to the side. Tightening specification. Refer to
Seal the transmission fluid cooler connections with plugs tak
en from Engine Bung Set - VAS6122- .
AG. Volkswagen AG d
agen oes
olksw not
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Remove ut the starter -A-. Refer to Electrical Equipment;
ho e o Rep.
ra
s a ; Starter; Starter, Removing and Installing .
Gr. s27 c
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le
un
Remove the lower bolt first.
pt
an
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itte
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rm
ab
pe
Caution
ility
ot
wit
, is n
h re
There is a risk of damaging the DSG Transmission Mecha
hole
spec
tronic - J743- with static electricity.
es, in part or in w
t to the co
Do not touch contacts in DSG Transmission Mechatronic
- J743- connector with hands.
To discharge any static electricity, touch the vehicle ground rrectness of i

l purpos

Release the Mechatronic connector twist lock -1- by turning it
nform
ercia
counter-clockwise and remove the connector.

m
a
com
tio
Remove all upper engine/transmission connecting bolts.

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These tools are suitable for this.

AG. Volkswagen AG d
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es, in part or in w
t to the co
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tion in
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t.
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rig ht
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by lksw
cted agen
Prote AG.

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
gine lifting eyes for the Engine Support Bridge - 10-222A- ,
these must now be removed.
Attach the Engine Support Bridge - 10-222A- as follows:
The following are needed:
Engine Support Bridge - Engine Support 18 - 10-222A/18-
Engine/Gearbox Support Shackle (2 pc.) - 10-222A/12- (quan
tity: 2) (are needed if the Spindles from the Engine Support
Bridge cannot be engaged in the engine lifting eyes). AG. Volkswagen AG d
agen oes
lksw not
Engine Support Bridge - Engine Support 29 - 10-222A/29-by V o gu
ara
(quantity 2) rised
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ut
Engine Support - Basic Set Square Pipe - T40091/1-
ss a (quantity ra
c
2)
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ility
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Engine Support - Supplement Kit - Spindle - T40093/3- (quan
wit
is n
tity: 2)
h re
ole,
spec
t to the co
Insert the Engine Support Bridge - Engine Support 29 -
10-222A/29- between the fender bolting edge and the fender
bolting plate underneath it on both sides of the vehicle.
rrectne
Installation position:
ss o
L = -1- Adapter is installed on the right side of the vehicle
cial p
f i
( Adapter locks in the hole on the fender).
nform
mer
atio
m
R (not illustrated here), Adapter is installed on the left side of

o
n
c
the vehicle.
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or
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The arrow -2- always points in driving direction

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Slide the Engine Support Bridge - Engine Support 18 - C py
ht. rig
10-222A/18- and two Engine Support - Basic Set Movable rig ht
py by
Joint - T40091/3- onto the Engine Support Bridge - 10-222A- .
co Vo
by lksw
cted agen
Prote AG.
Tighten the Engine Support Bridge - 10-222A- on the Engine
Support Bridge - Engine Support 29 - 10-222A/29- .
-A- = Engine Support Brackets - T40093/3-6- ( next illustration).
Remove the filler tube for the windshield washer system wash
er fluid reservoir. Refer to Electrical Equipment; Rep. Gr.
92 ; Windshield Washer System; Windshield Washer Fluid
Reservoir, Removing and Installing .

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
gitudinal members (the right longitudinal member is illustrated
here).
If necessary, carefully unclip the A/C system pipe in the front
area. Do not disconnect the line system. Refer to Heating,
Ventilation and Air Conditioning; Rep. Gr. 87 ; Coolant Circuit;
Component Location Overview - Coolant Circuit .
. Volkswagen AG
gen AG does
The Engine Support Brackets - T40093/3-6- locks Vol
krespectively
swa not
with the pins -A- behind the tab on the longitudinal
ed
by member gu
ara
-arrow-. ho
ris nte
eo
t
au ra
Install the Engine Support - Supplement
ss Kit - Spindle - c
T40093/3- .
ce
le
un
pt
an
d
itte
Connect the Engine Support - Supplement Kit - Spindle -
y li
erm
ab
T40093/3- to the Engine Support Bridge - 10-222A- using the
ility
ot p
Engine Support - Basic Set Square Pipe - T40091/1- and ten
wit
is n
sion it ( previous illustration).
h re
ole,
Then engage the spindles in the lifting eyes.
spec
t to the co
Pretension the engine/transmission assembly and Engine
Support Bridge via the Spindles .
Remove the noise insulation. Refer to Body Exterior; Rep.
rrectne
Gr. 66 ; Noise Insulation; Overview - Noise Insulation .
Remove the lower section of the left front wheel housing liner.
ss o
Refer to Body Exterior; Rep. Gr. 66 ; Wheel Housing Liner;
cial p
f i
Overview - Front Wheel Housing Liner .
nform
mer
atio
m
o
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c
i
or
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sd
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them up.
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t.
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Vo
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cted agen
Prote AG.
If equipped, disconnect the connector -1- from the Oil Level

Thermal Sensor - G266- .

Remove the bolts -11- and then remove the pendulum

agen
AG. Volsupport
kswagen AG
does
from the transmission. Volksw not
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ed ran
Secure the subframe before removing.
ho
ris Refer to Suspen tee
sion, Wheels, Steering; Rep. Gr.
aut 40 ; Subframe; Subframe, or
ac
Securing . ss
ce
e
nl
pt
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an
itte
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Note
erm
ab
ility
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If the subframe is not secured, a vehicle alignment must be per
, is n
h re
formed later.
hole
spec
es, in part or in w
Remove the subframe without the steering gear. Refer to
t to the co
Suspension, Wheels, Steering; Rep. Gr. 40 ; Subframe; Sub
frame without Steering Gear, Removing and Installing .
rrectness of i
Remove both driveshafts from the transmission. Refer to
Suspension, Wheels, Steering; Rep. Gr. 40 ; Driveshaft, Re
l purpos
moving and Installing .
nform
ercia
Secure the driveshafts to the suspension strut using a Ten

sioning Strap - T10038- .
m
at
om
ion
c
Do not damage the surface of the shafts.
in t
or
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ate
do
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cum
for
en
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t.
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t. rig
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by
cted agen
Prote AG.
Remove the bolts -1 and 2- from the transmission bracket

-A-.
Always replace the bolts.
Lower the engine/transmission approximately to the dimen

sion -a- using the spindles on the Engine Support Bridge -
10-222A- .
Dimension -a- = approximately 50 mm

Remove the transmission bracket in direction of -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
To remove the transmission 0D9, the Transmission Support ris -
ed
nte
3282- is equipped with the Transmission Support - Mounting
ut
h Plate
o eo
ra
a
- 3282/42A- and positioned on the Engine and Gearboxs Jack -
s c
VAS6931- .
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un
pt
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d
itte
Align the arms of the Transmission Support so that they match
y li
rm
ab
up with the holes in the Transmission Support - Mounting Plate
pe
ility
42A - 3282/42A- .
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Install the mounting element as illustrated on the Transmission
h re
hole
Support - Mounting Plate 42A - 3282/42A- .
spec
es, in part or in w
Place the Engine and Gearbox Jack - VAS6931- under the
t to the co
vehicle.
The arrow symbol on the Transmission Support - Mounting
rrectness of i
Plate 42A - 3282/42A- points in the direction of travel.
l purpos
Align the Transmission Support - 3282- so that it is parallel to

the transmission.
nform
ercia
Install the Transmission Support - Pins 29 - 3282/29- in the

transmission.
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tion in
Secure both the other support elements to the transmission as
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thi
shown.
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Contrary to the illustration of the Adjusting Plate , the front rig ht
py by
support element is shown attached to the transmission with an
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M10 x 50 mm bolt -arrow-. Install a M12 bolt between the
agen
Prote AG.
mount and the transmission housing.
DSG transmission 02E AWD is shown in the illustration. The
support elements on the 0D9 FWD transmission are iden
tical.
Support the transmission by lifting it from underneath using the

Engine and Gearbox Jack - VAS6931- .
The transmission is disconnected from the engine in this position.
Remove the remaining engine/transmission connecting bolts.
Remove the transmission from the engine (alignment
sleeves), and also pay attention to the selector lever cable.
Tilt the transmission to the left by adjusting the spindle for the
Transmission Support - 3282- .

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.
Transmission, transporting. Refer to

Install the transmission. Refer to wage
es n
3.2 Transmission, Installing, page 91y V. olks ot g
u b ara
ed nte
oris e
3.1.2 Transmission, Removing, Vehicles with ss
au
th or
ac
Turbo Diesel Engine
ce
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un
pt
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itte
Brief Description
y li
erm
ab
ility
The transmission is removed downward separately.
ot p
wit
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From above:
h re
ole,
spec
The battery, air filter and starter are removed. Engine and trans
mission are supported before the left subframe mount is removed.
t to the co
From underneath:
rrectne
The -subframe- is removed together with the
-pendulum support- and -both control arms-. The -steering gear-
remains in the vehicle.
ss o
cial p
Both driveshafts are disconnected from the transmission and re
f in
main inside the wheel bearing housings. Occasionally they will be
form
mer
moved to the side, but they still remain on the vehicle.

atio
om
n
c
i
or
n thi
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t.
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Cop py
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by
cted agen
Prote AG.
Transmission Support - 3282-
Transmission Support - Mounting Plate 42A - 3282/42A-
Support Elements for transmission (determine when mounting
the Mounting Plate on the Transmission Support )
Transmission Support - Pins 29 - 3282/29-
Torque Wrench 1331 5-50Nm - VAG1331-
Engine and Gearbox Jack - VAS6931-
Hose Clamps - Up To 25mm - 3094- or Hose Clamps - Up To
40mm - 3093-
Engine Support - Basic Set - T40091-

Engine Support - Supplement Kit - T40093A-

Engine Bung Set - VAS 6122-
Removing
Disconnect the battery ground cable. Refer to Electrical
Equipment; Rep. Gr. 27 ; Battery; Battery, Disconnecting eand
Connecting . olks
wag es n
o V t gu
by ara
Remove the engine cover. Refer to Rep. Gr.
ris 10 ; Engine
ed nte
Cover; Engine Cover, Removing and Installing
au
tho
. eo
ra
ss c
Remove the air filter housing. Refer to Rep. Gr. 23 ; Air
ce
e
nl
Filter; Air Filter Housing, Removing and Installing .
pt
du
an
itte
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erm
ab
ility
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hole
spec
Remove the battery and the battery tray -1- -arrows-. Refer to
es, in part or in w
Electrical Equipment; Rep. Gr. 27 ; Battery, Removing and
t to the co
Installing .
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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Remove the selector lever cable from the transmission

rp
cu
o
m
f
-arrows-.
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
Vol Note
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d by ara
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Use pliers
ut
ho to remove the lock washer from the cable e obracket.
ra
Dossnot use a sharp-edged lever. Otherwise the selector
a c lever
cable could get damaged.
ce
e
nl
pt
du
an
Remove the cable bracket -2- from the transmission, if nec
itte
y li
essary. Remove the bolts -1- and the lock washer -3-.
erm
ab
ility
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Replace the bolts -1- and the lock washers.
wit
, is n
h re
Bolt tightening specification -1- 20 Nm +90.
hole
spec
es, in part or in w
t to the co
Caution
rrectness of i
Risk of damaging the selector lever cable.
l purpos
Remove the selector level cable from the cable bracket

when lowering transmission.
nform
ercia

m
at
om
ion
c
Place a lint-free cloth on to transmission fluid cooler and trans

in t
or
his
e
mission to absorb escaping coolant.

at
do
priv
cum
for
en
WARNING
ng
t.
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Cop py
t. rig
Risk of scalding due to hot steam and hot coolant.
gh ht
pyri by
Vo
o
by c lksw
The cooling system is under pressure when the engine is
Prote
cted AG.
agen
warm.
Reduce the pressure by covering the coolant reservoir cap
Clamp the coolant hose with the Hose Clamps - Up To 25mm

- 3094- .
Loosen the hose clamps -arrows- and remove the coolant ho
ses from the transmission fluid cooler.
If equipped, remove the bolts -1- and move the Transmission
Coolant Valve - N488- to the side. Tightening specification.
Refer to
Seal the transmission fluid cooler connections with plugs tak
en from Engine Bung Set - VAS 6122- .

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

tronic - J743- with static electricity.
Do not touch contacts in DSG Transmission Mechatronic
- J743- connector with hands.
To discharge any static electricity, touch the vehicle ground

Release the Mechatronic connector twist lock -1- by turning it
counter-clockwise and remove the connector.
Remove all upper engine/transmission connecting bolts.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
These tools are suitable for this.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
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un
pt
an
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itte
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rm
ab
pe
ility
ot
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, is n
One bolt is located inside the hole for the starter -arrow-. Use
h re
Socket - Xzn 14 - T10061- to remove the bolt.

hole
spec
es, in part or in w
Remove windshield wiper arms. Refer to Electrical Equip

t to the co
ment; Rep. Gr. 92 ; Windshield Wiper System; Windshield

Wiper Arms, Removing and Installing .
rrectness of i
Remove the plenum chamber cover. Refer to Body Exterior;

Rep. Gr. 50 ; Bulkhead; Plenum Chamber Cover, Removing
l purpos
and Installing .
If there are hose and cable connections located near the en
nform
ercia
gine lifting eyes for the Engine Support Bridge - 10-222A- ,

these must now be removed.
m
a
com
tion in
r
te o
thi
s
iva
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fo
en
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t.
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cted agen
Prote AG.

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-
Engine Support Bridge - Engine Support 31 - Adapter 2-
10-222A/31-2- olks
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Engine Support - Basic Set - Square
ris
ed Pipe - T40091/1- nte
tho eo
Engine Support - Basic SetssMovable
au Joint - T40091/3- ra
c
ce
e
Engine Support - Supplement Kit Spindle - T40093/3-

nl
pt
du
an
itte
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Engine Support Brackets - T40093/3-6-
erm
ab
ility
ot p
Engine/Gearbox Support Shackle (2 pc.) - 10-222A/12-
wit
, is n
h re
Remove the caps over the suspension strut threaded connec
hole
tions.
spec
es, in part or in w
Place the Engine Support Bridge - Engine Support 31 Adapter
t to the co
1 - 10-222A/31-1- and Engine Support Bridge - Engine Sup
port 31 Adapter 2 - 10-222A/31-2- on the suspension strut
mounts.
rrectness of i
The tabs -arrow- face the engine compartment.
l purpos
Slide the Engine Support - Supplement Kit Adapter 3 -
nform
ercia
T40091/3- onto the Engine Support Bridge - 10-222A- .

m
at
Fasten the Engine Support Bridge - 10-222A- on the Engine
om
ion
Support Bridge - Engine Support 31 Adapter 1 - 10-222A/31-1-
c
in t
or
and on the Engine Support Bridge - Engine Support 31 Adapt
his
ate
er 2 - 10-222A/31-2- .
do
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or
-A- = Engine Support Brackets - T40093/3-6- ( next illustration)

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en
ng
t.
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Cop py
t. rig
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pyri by
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by c lksw
cted agen
Prote AG.

Remove fuel filter and set off to the side. Do not open the line
system. Refer to Rep. Gr. 20 ; Overview - Fuel Filter .
If present, remove wires from the front area of the tab on the
longitudinal member -arrow-. Do not disconnect line system.
Position the Engine Support Brackets - T40093/3-6- on the
right longitudinal member.
If necessary, carefully unclip the A/C system pipe in the front
area. Do not disconnect the line system. Refer to Heating,
Ventilation and Air Conditioning; Rep. Gr. 87 ; System Over
view - Refrigerant Circuit .
The Engine Support Brackets - T40093/3-6- locks with the pins
-A- behind the tab on the longitudinal member -arrow-.
Install the Engine Support - Supplement Kit Spindle -
T40093/3- .
Connect the Engine Support - Supplement Kit Spindle -
T40093/3- over the Engine Support - Basic Set Square Pipe -
T40091/1- with the Engine Support Bridge - 10-222A- and
tension it ( previous illustration).
The Engine Support - Basic Set Square Pipe - T40091/1- must
be flush with the Engine Support - Basic Set Movable Joint -
T40091/3- and the Engine Support - Supplement Kit Spindle
- T40093/3- ( previous illustration).
Then engage the Spindles in the lifting eyes, as shown.
Pretension the engine/transmission assembly and Engine
Support Bridge - 10-222A- via the Spindles .
Loosen left and right front wheel bolts.
Lift the vehicle, all four mounts from lifting platform at the same
height.
Remove the front wheels.
n AG. Volkswagen A ge G do
swa es
Remove the lower section of the by
Vleft
olk front wheel housing liner.not g
ua
Refer to Body Exterior; Rep.
ris
e Gr. 66 ; Wheel Housing Liner;
d ran
tee
Overview - Front WheeluHousing
tho Liner . or
a ac
ss
ce
le
un
pt
an

d
itte
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rm
ab
pe
ility
them up.
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
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cum
fo
en
ng
t.
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Cop py
t. rig
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co Vo
by lksw
cted 3. Transmission, Removing and Installing
agen
Prote AG.
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.
Do not load the decoupling element.
Do not damage the wire mesh on the decoupling element.
Disconnect the exhaust system at the clamping sleeve and

remove the exhaust system bracket from the subframe
-arrows-. Refer to Rep. Gr. 26 ; Exhaust Pipe/Muffler;
Overview - Muffler .
Tie up the front exhaust pipe.
G. Volkswagen AG d
Remove the bolts -11- and then remove the pendulumlksupport
swa
gen A oes
not
from the transmission. by
Vo gu
ara
d
ise nte
Secure the subframe before removing. Refer ut
ho to Suspen
r eo
ra
sion, Wheels, Steering; Rep. Gr. 40 ; Subframe;
ss
a Subframe, c
Securing .
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le
un
pt
an
d
itte
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erm
ab
Note
ility
ot p
wit
is n
If the subframe is not secured, a vehicle alignment must be per

h re
ole,
formed later. spec

t to the co
Remove the subframe without the steering gear. Refer to

Suspension, Wheels, Steering; Rep. Gr. 40 ; Subframe; Sub
frame without Steering Gear, Removing and Installing .
rrectne
If equipped, remove the heat shield above the right driveshaft

s
-arrows-.
s o
cial p
f in
Remove both driveshafts from the transmission. Refer to

form
mer
Suspension, Wheels, Steering; Rep. Gr. 40 ; Driveshaft, Re

atio
moving and Installing .

om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
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Secure the driveshafts to the suspension strut using a Ten

sioning Strap - T10038- .
Do not damage the surface of the shafts.
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Remove the bolts -1 and 2- from the transmission bracket
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-A-.
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Always replace the bolts.
rrectness of i
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Lower the engine/transmission approximately to the dimen
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sion -a- using the spindles on the Engine Support Bridge -
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10-222A- .
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Dimension -a- = approximately 50 mm C py
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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- .
Align the arms of the Transmission Support so that they match
up with the holes in the Transmission Support - Mounting Plate
42A - 3282/42A- .
Install the mounting element as illustrated on the Transmission
Support - Mounting Plate 42A - 3282/42 A- .
vehicle.
The arrow symbol on the Transmission Support - Mounting
Plate 42A - 3282/42A- points in the direction of travel.
Align the Transmission Support - 3282- so that it is parallel to
the transmission.
Install the Transmission Support - Pins 29 - 3282/29- in the
transmission.
Secure both the other support elements to the transmission as
shown.
Note
Contrary to the illustration of the Adjusting Plate , the front

support element is shown attached to the transmission with an
M10 x 50 mm bolt -arrow-. Install a M12Abolt
G. Vobetween
lkswagen Athe
mount and the transmission housing.
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DSG transmission 02E AWD
ris
ed is shown in the illustration. The
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support elements on the tho0D9 FWD transmission are iden eo
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Support the transmission by lifting it from underneath using the

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Engine and Gearbox Jack - VAS6931- .

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The transmission is disconnected from the engine in this position.

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Remove the remaining engine/transmission connecting bolts.

hole
spec
Remove the transmission from the engine (alignment

es, in part or in w
t to the co
sleeves), and also pay attention to the selector lever cable.

Tilt the transmission to the left by adjusting the spindle for the
Transmission Support - 3282- .
rrectness of i
Slightly turn and lower the transmission. Make sure that the
l purpos
right flange shaft -1- is guided past when lowering the inter
mediate plate -arrow-.
nform
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Note
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Pay attention to all of the lines when lowering the transmission.

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Transmission, transporting. Refer to

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3.2 Transmission, Installing
Caution


Bolts - Engine to Transmission Connecting
Bolts - Subframe Mount
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Lockwashers - Selector
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Install in reverse torder
ho
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or
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Note
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Refer to Transmission, Removing
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3.1 Transmission, Removing, page 72 for a list of the spe
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cial tools needed.
h re
hole
After installing a new transmission, reprogram the immobil
spec
es, in part or in w
izer.
t to the co
rrectness of i
Note
l purpos
Always replace the needle bearing -arrow- after separating the

engine and transmission.
nform
ercia
If the needle bearing in the crankshaft is damaged, the gears

m
will no longer shift correctly.

at
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Replace the needle bearing in the crankshaft. Refer to Rep.

his
ate
Gr. 13 ; Crankshaft; Needle Bearing in Crankshaft, Replacing .

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Transmission pins (not splines) must also be lightly lubricated.

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Make sure both alignment sleeves between the engine and C py
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the transmission are correctly seated.
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Make sure the intermediate plate fits correctly. cted agen
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Place the transmission with the Transmission Support - 3282-
d
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on the Engine and Gearbox Jack - VAS 6931- .
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vehicle. The arrow symbol on the Transmission Support -
h re
Mounting Plate 42A - 3282/42A- points in the direction of travel
hole
spec
of the vehicle.
es, in part or in w
t to the co
Tilt the transmission to the left by adjusting the spindles on the
Transmission Support - 3282- . The lift the transmission.
rrectness of i
Pay attention to the selector lever cable when lifting the trans
mission. Guide the cable into the cable bracket as early as
l purpos
possible.
The cable is not lubricated.
nform
ercia
Align the transmission to the engine and position on the cyl
m
a
inder block.
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Guide the engine and transmission together by hand until the en

te o
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tire surface of both flanges come into contact with one another.
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Adjust the transmission mount until the engine and transmis
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Turn the crankshaft slightly if necessary.
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Be careful not to get any lines caught when installing the trans
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Tighten the bolts -5 through 9- to the tightening specification.

After transmission was bolted to engine at bottom, remove the
Transmission Support - 3282- from transmission.
Tighten the upper engine/transmission bolts -1, 3 and 10- to
the tightening specification using the Insert Tool - 18mm -
T10179- .
The bolt -3- is located in the starter hole. Use the Socket - Xzn 14
- T10061- for this bolt.
Align the engine/transmission assembly free of tension. Refer
to Engine Mechanical, Fuel Injection and Ignition; Rep. Gr.
10 ; Subframe Mount; Subframe Mount, Adjusting .

Install the left subframe mount as follows: wage

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Replace all the bolts -1 and 2-. ed by ua
ran
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Install the new bolt first hand-tight.
auth or
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Install the bolts -1- in the transmission bracket -A-.
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The align the engine/transmission in its installation position.
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Lift until the transmission bracket is touching the transmission
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mount completely.
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Caution
spec
es, in part or in w
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There is a risk of damaging the threads in transmission bracket
by inserting the bolts at an angle.
Before installing the bolts -2-, the transmission bracket
rrectness of i
and transmission mount support arm must be absolutely
l purpos
parallel to each other. If necessary, lift the back of the

transmission using the Engine and Gearbox Jack .
nform
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Pry the transmission bracket -A- into the seat using a screw
a
com
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driver while tightening the bolts -2-.
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Remove the Engine Support Bridge - 10-222A- only when the

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bolts for the left and right subframe mount have been tightened
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to the specification.
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Remove the Engine Support Bridge - 10-222A- .

Install the starter. Refer to Electrical Equipment; Rep. Gr.
27 ; Starter; Starter, Removing and Installing .
Connect the connector -A- on the DSG Transmission Mechatronic

- J743- as follows:
The arrow -D- on the DSG Transmission Mechatronic - J743-
-B- must line up with the connector -A- as well as with the tab
-C-.
Connect the connector -A- carefully all the way and then turn
the lock clockwise in direction of -arrow-.
Attach the drive axles to the transmission. Refer to Sus
pension, Wheels, Steering; Rep. Gr. 40 ; Drive Axle; Drive
Axle, Removing and Installing .
Install the heat shield over the right drive axle, if equipped.
Refer to Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive
Axle; Drive Axle, Removing and Installing .
Install the subframe. Refer to Suspension, Wheels, Steer
ing; Rep. Gr. 40 ; Subframe; Subframe with Steering Gear,

Attach the pendulum support to the transmission by tightening

the bolts -11-. Refer to Rep. Gr. 10 ; Subframe Mount;
Overview - Subframe Mount .
AG. Volkswagen AG d
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Selector lever cable lock washers -arrows- must be replaced.

page 68 .
Install the charge air pipe. Refer to Engine Mechanical, Fuel
Injection and Ignition; Rep. Gr. 21 ; Charge Air System; Over
view - Charge Air System .
Install the coolant hoses on the transmission fluid cooler.
Attach the cable bracket to the transmission cover.
Install the battery tray and the battery. Refer to Electrical
Equipment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and
Connecting .
Gasoline engine. Refer to Rep. Gr. 24 ; Air Filter; Air Filter
Install the engine cover. Refer to Rep. Gr. 10 ; Engine
Cover; Engine Cover, Removing and Installing .
Check the coolant level and fill if necessary. Refer to Engine
Mechanical, Fuel Injection and Ignition; Rep. Gr. 19 ; Cooling
System/Coolant; Coolant, Draining and Filling .
Check the fluid level and fill if necessary. Refer to
Install the lower section of the left front wheel housing liner.
66 ; Noise Insulation; Overview - Noise Insulation . wage
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Vol t gu
Attach the front wheels. Refer to Suspension, eWheels,
db
y ara
Steering; Rep. Gr. 44 ; Wheels, Tires; Wheel Bolts,
horis Tightening nte
eo
Specifications . sa
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Transmission to engine. Refer to

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Transmission bracket to transmission. Refer to

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4 Subframe Mount, page 97 .

hole
spec
Cable bracket on the transmission cover. Refer to

es, in part or in w
t to the co

Subframe mount to transmission bracket. Refer to
4.1 Overview - Subframe Mount, page 97 .
rrectness of i
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Golf 2015 , Golf Variant 2015 AG. Volkswagen
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3.3 Transmission Tightening Specifications aut
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Transmission to Engine
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Item itte Bolt Nm
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1 M12 x 55 80
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With Insert Tool -
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18mm T10179:
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65 Nm
spec
es, in part or in w
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2 M10 x 45 40
Starter to trans
mission
rrectness of i
3 M12 x 55 80
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Is accessible on
ly through the
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removed starter
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4 M10 x 45 40
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Starter to trans
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6 M10 x 50 40
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7 M10 x 50 40
8 M10 x 50 40
9 M12 x 65 80
or M12 x 70
or M12 x 80
10 M12 x 55 80
With Insert Tool -
18mm T10179:
65 Nm
A Alignment sleeve for centering
Component Tightening Specification

Cable bracket on the transmis 10 Nm
sion cover
Transmission Coolant Valve - 9 Nm
N488- bolts

4 Subframe Mount
4.1 Overview - Subframe Mount, page 97 . AG. Volkswagen AG d
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1 - Bolt ss
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For the tightening spec
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ification. Refer to En
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Injection and Ignition;
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Rep. Gr. 10 ; Subframe
, is n
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Mount; Overview - Sub
hole
spec
frame Mount .
es, in part or in w
t to the co
2 - Engine Support
Refer to Engine Me
chanical, Fuel Injection
rrectness of i
and Ignition; Rep. Gr.
10 ; Subframe Mount;
l purpos
Overview - Subframe
Mount .
nform
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3 - Engine Mount
m
at
Refer to Engine Me
om
ion
chanical, Fuel Injection
c
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and Ignition; Rep. Gr.
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10 ; Subframe Mount;
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Overview - Subframe
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Mount .
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4 - Bolt
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For the tightening spec co Vo
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Mount; Overview - Sub
frame Mount .
5 - Bolt
For the tightening spec
Mount; Overview - Subframe Mount .
6 - Bolt
For the tightening specification. Refer to Engine Mechanical, Fuel Injection and Ignition; Rep. Gr. 10 ;
Subframe Mount; Overview - Subframe Mount .
7 - Bolt
8 - Pendulum Support
9 - Bolt
For pendulum support to subframe
10 - Bolt
For pendulum support to transmission
4. Subframe Mount 97
Transmission with threaded insert. Refer to
Fig. Transmission with Threaded Insert (for Example Heli Coil) for Attaching the Pendulum Support ,
page 99
11 - Bolt
For pendulum support to transmission
Transmission with threaded insert. Refer to
Fig. Transmission with Threaded Insert (for Example Heli Coil) for Attaching the Pendulum Support ,
page 99
12 - Bolt
60 Nm + 90
Replace after removing agen AG. Volkswagen AG do
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Tightening sequence.
horis Refer to page 99 . tee
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13 - Bolt ss
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60 Nm + 90
pt
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For transmission mount to transmission bracket wit

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Tightening sequence. Refer to page 99 . spec

es, in part or in w
14 - Transmission Mount
t to the co
Check the adjustment. Refer to Engine Mechanical, Fuel Injection and Ignition; Rep. Gr. 10 ; Subframe
Mount; Subframe Mount, Checking Adjustment
rrectness of i
Adjusting. Refer to Engine Mechanical, Fuel Injection and Ignition; Rep. Gr. 10 ; Subframe Mount;
Subframe Mount, Adjusting
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15 - Bolt
nf
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Transmission mount to chassis

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Subframe Mount; Subframe Mount, Adjusting .

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16 - Bolt
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40 Nm + 90
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For transmission bracket to transmission Cop py
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Tightening sequence. Refer to page 99 .
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17 - Transmission Bracket
agen
Prote AG.
Illustration does not correspond to version in vehicle

18 - Bolt
40 Nm 90
For transmission bracket to transmission
Tightening sequence. Refer to page 99 .

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Direct Shift
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Transmission with ThreadedautInsert (for Example Heli Coil) for or
ac
Attaching the Pendulum Support
ss
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Note
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ility
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There are threaded inserts (for example Heli Coil) in the pen
is n
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dulum support fastening holes.
ole,
spec
Identified by: collar on the first thread -arrow-.
t to the co
Make sure to use the appropriate bolts and observe the tight
ening specification. Refer to Engine Mechanical, Fuel In
jection and Ignition; Rep. Gr. 10 ; Subframe Mount; Overview
rrectne
- Subframe Mount ..
ss o
cial p
f
Install the Left Subframe Mount as Follows:
inform
mer
Replace all the bolts -1 and 2-.
atio
om
Install the new bolt first hand-tight.
n
c
i
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Install the bolts -1- in the transmission bracket -A-.

t
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Pry the transmission bracket -A- into the seat using a screw
r
fo
en
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driver while tightening the bolts -2-.

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4. Subframe Mount 99
5 Transmission, Transporting
Engine Sling - 2024A-
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Transmission Support Jig -Vo3336-
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Shop Crane - VAS6100-
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Always secure heaving
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parts when transporting them. c
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Remember there is oil in the transmission. Do not turn the trans
pt
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mission with the vents facing downward when transporting or
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when it is on the assembly stand. The oil will leak out.
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Note
hole
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Remove the bleed cap if necessary and use oil-tight plugs.
t to the co
Transmission, Transporting
rrectness of i
Install the Engine Sling - 2024A- on the transmission and se
l purpos
cure with the clamp.
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The transmission can also be lifted using the Transmission Sup
ht
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port Jig - 3336- .
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Prote AG.

6 Transmission, Disassembling and

Assembling
6.1 Overview - Transmission
1 - Transmission Cover
Removing and instal
ling. Refer to
1.2 Mechatronic, Re gen AG
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page 30 . rised b ara
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2 - Seal au ac
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3 - Bolt
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For attaching the DSG
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Transmission Mecha
hole
tronic - J743- to the
spec
transmission housing
es, in part or in w
t to the co
Tightening specification
and sequence. Refer to
Fig. Tightening
rrectness of i
Specification and Se
quence for DSG Trans
l purpos
mission Mechatronic -
J743- , page 30
nform
ercia
Quantity: 10
m
at
4 - DSG Transmission Mecha

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ion
tronic - J743-
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Allocate using the trans

at
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mission code letters.

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Refer to the Parts Cata

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Removing and Installing
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AG.

page 30 .
Removing and installing
with transmission re
moved. Refer to
1.2.2 DSG Transmission Mechatronic J743 , Removing and Installing, Transmission Removed, page
39
5 - Bolt
Fig. Tightening Specification and Sequence for DSG Transmission Mechatronic -J743- , page 30
For attaching the transmission cover with seal to the transmission housing
Quantity: 5
6 - Clutch End Cover
For the dual clutch -7-.
Removing and installing. Refer to 1.2 Clutch End Cover, Removing and Installing, page 15 .
6. Transmission, Disassembling and Assembling 101

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
Pressed into the transmission housing
9 - Bleed Cap
Placed on bleed pipe -8-.
10 - Nut
20 Nm
11 - Selector Lever
Insert so that master spline aligns with shift rod
12 - Seal
For the selector shaft
Replacing. Refer to 2.9 Selector Shaft Seal, Replacing, page 69 .
13 - Bolt
20 Nm + 90
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14 - Transmission Oil ris Cooler
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Removing auand installing. Refer to ac
ss
8.1 Transmission Fluid Cooler, Removing and Installing, page 105 .
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15 - O-Rings
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16 - Cable Mounting Bracket

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For selector lever cable

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17 - Bolt
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20 Nm + 90
rrectness of i
Quantity: 2
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18 - Filter Housing
20 Nm
nform
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19 - O-Ring
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tion in
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20 - Transmission Fluid Filter

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Information on changing filter 8.3 Transmission Fluid Filter, Removing and Installing, page 110
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Replacing. Refer to 9 Transmission Fluid, page 113 .

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21 - Ignore, discontinued Cop py
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22 - Ignore, discontinued py by
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23 - Alignment Pin Prote AG.
Quantity: 2
For centering the transmission fluid pump to the transmission housing
24 - Seal

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25 - TransmissionrisOil
ed Pump ran
tee
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Removing au and installing. Refer to
t or
ac
ss 8.2 Transmission Fluid Pump, Removing and Installing, page 107 .
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26 - Transmission Fluid Pump Cover
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With seal
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27 - Bolt
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rrectness of i
Fig. Tightening Specification and Sequence of the Transmission Fluid Pump Cover -A-. , page 30
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28 - Bolt
nf
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There are different bolts for the transmission fluid pump. Refer to page 109
orm
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atio
Quantity: 4
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29 - Overflow Pipe
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3 Nm
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Plastic
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To drain the transmission fluid, remove the drain and check plugs. Refer to -item 31-
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Item 31 (page 103) , and remove the overflow pipe. t. C rig
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The length of the overflow pipe determines the fluid level inside the transmission op Vo
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Allocate according to the Parts Catalog. Prote AG.
30 - Seal
31 - Transmission Fluid Drain- and Check Plug
45 Nm
There is an overflow pipe with a 8 mm inner hex behind this bolt -item 29- Item 29 (page 103)
Drain the transmission fluid via the drain- and check plug and removed overflow pipe
6. Transmission, Disassembling and Assembling 103

7 Securing on Engine and Transmis

sion Holder
Holding Plate - VW309-
or Holding Plate - VW309A-
Transmission Support - VW353-
Engine and Gearbox Bracket - VAS6095A-
Remember there is oil in the transmission. Do not turn the trans
mission with the vents facing downward when transporting or
when it is on the assembly stand. The fluid will leak out.
Note
Remove the bleed cap if necessary and seal using suitable oil-
tight plugs.
Secure the transmission on the Transmission Support - VW353- .
AG. Volkswagen AG d
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pe
ility
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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Prote AG.

8 Transmission Fluid Circuit

8.1 Transmission Fluid Cooler, Removing and Installing, page
105
8.2 Transmission Fluid Pump, Removing and Installing, page
107
page 110
8.1 Transmission Fluid Cooler, Removing

and Installing
Hose Clamps - Up To 25mm - 3094-
Engine Bung Set - VAS6122-
Caution


Bolts - Transmission Fluid Cooler
olks
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V
by ua
O-rings - Transmission Fluid
ris
ed Cooler ran
tee
tho or
Removing ss au ac
ce
e

nl
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itte
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erm
ab
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wit
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hole
spec

es, in part or in w
t to the co

Remove the battery and the battery tray if necessary. Refer to
Electrical Equipment; Rep. Gr. 27 ; Battery; Battery, Dis
rrectness of i
connecting and Connecting .

l purpos
Place lint-free cloth on to transmission fluid cooler and trans

mission to absorb exiting coolant.
nform
mercia
at
WARNING
om
ion
c
in t
or
Risk of burning due to hot steam and hot coolant.

his
ate
do
riv
When engine is warm, the cooling system is under pres

p
cum
or
sure.
f
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ng
t.
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Reduce pressure by cover coolant expansion tank cap C py
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Prote AG.
8. Transmission Fluid Circuit 105

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-.
Caution
Coolant must not drip into transmission!
AG. Volkswagen AG d
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Installing orise
d
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u
Replace the O-rings -C- on thess atransmission fluid cooler -B-. ra
c
ce
e
Mount the transmission fluid cooler -B-, while doing this, pay
nl
pt
du
an
attention to the O-rings -C-.

itte
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erm
ab
Install and tighten the new bolts -arrows-.

ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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lkswage es n Golf 2015 , Golf Variant 2015
o ot g
byV ua Direct Shift Gearbox - Edition 09.2015
ed ra
ris nte
tho eo
Attach au
the
ss coolant hoses to the transmission fluid cooler and
ra
c
remove the Hose Clamps - Up To 25mm - 3094- .
ce
e
nl
pt
du
an
Install the battery and the battery tray if they were removed
itte
y li
earlier. Refer to Electrical Equipment; Rep. Gr. 27 ; Battery;
erm
ab
Battery, Disconnecting and Connecting .
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Check the coolant level and add if necessary. Refer to En

gine Mechanical, Fuel Injection and Ignition; Rep. Gr. 19 ;
nform
ercia
Cooling System/Coolant; Coolant, Draining and Filling .

m
at
After repairing, check the transmission fluid level and fill. Refer
om
io
to 9.1 Transmission Fluid Level, Checking, page 113 .
n
c
in t
or
his
ate
do
riv
Caution
p
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for
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ng
t.
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Do not start engine during coolant level test if the transmission
Co
op py
fluid has not been filled yet. t. C rig
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Prote AG.
Transmission fluid cooler at transmission. Refer to
8.2 Transmission Fluid Pump, Removing

and Installing
Wrench - Pump/Injector Long Reach - T10054-
Brief Description
Transmission fluid pump can be replaced without removing trans
mission. The vehicle must be raised and any covers installed on
bottom of front end must be removed. The control arm to sus
pension strut connection does not need to be separated. The
driveshaft also does not have to be removed. It is not necessary
to perform a basic setting. Only the dual-clutch transmission flu
id and transmission fluid pump cover have to be replaced.
Removing
Loosen the left front wheel bolts.
Raise the vehicle and remove the left front wheel.
Remove the left front wheel housing liner. Refer to Body
Exterior; Rep. Gr. 66 ; Wheel Housing Liner; Front Wheel
Housing Liner, Removing and Installing .


Remove the Transmission fluid drain- and check plugs
-arrow- and drain the transmission fluid.
Caution

transmission.
A plastic overflow pipe is located in this hole (with 8 mm hex

socket head). Its length determines the fluid level in the trans
mission.
Remove this overflow pipe and drain the remaining transmis
sion fluid.
Reinstall the overflow pipe.
Replace the bolt seal -arrow-.

In regard to contaminated fluid, also read the information on
changing the oil filter. Refer to
page 110 .
The Used Oil Collection and Extraction Unit - SMN372500- or
a Drip Tray remains under the transmission.
Caution
Fluid will leak out of the cover when the bolts are removed. Risk
of injury due to hot transmission fluid.
gen AG
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d
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ho e
The bolts -arrows-
sa
ut
and remove the transmission fluid pump or ac
cover -A-. s
ce
e
nl
pt
du
an
itte
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Note
erm
ab
ility
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wit
, is n
Always replace the cover and the transmission fluid pump bolts
h re
after removing.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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cu
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f
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t.
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by c lksw
108
cted agen
Prote
Rep. Gr.34 - Controls, Housing
AG.
Remove the bolts -arrows-. Remove the transmission fluid

pump -1- from the alignment pin and the input shaft.
AG. Volkswagen AG d
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aut ra
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nl
pt
du
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erm
ab
ility
ot p
Remove the top bolt with the Wrench - Pump/Injector Long Reach
wit
, is n
- T10054- .
h re
hole
spec
Installing
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
c
Install the transmission fluid pump input shaft -A- all the way
or
thi
into the transmission. Turn the input shaft while doing this.
te
sd
iva
o
r
rp
Always use a new metal seal -B-. cu

o
m
f
en
ng
t.
The two alignment pins -C- must be inside the transmission
yi Co
op
housing.
C py
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When positioning the transmission fluid pump, pay attention
co Vo
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cted
to the driveshaft splines -A- and the correct seating on the
agen
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alignment pins -C-.
Different Transmission Fluid Pump Bolts -1-

All Four Bolts -arrows- with Flat Heads
Replace the bolts after removing them.
Tightening Specification
5 Nm + +90 (1/4 turn)

Direct Shift Gearbox
wage - Edition 09.2015
e
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Vol t gu
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3 Bolts with Flatris Head, Top Bolt -arrow-
ed
with Countersunk nte Head
utho eo
Replace the
ss bolts after removing them.
a ra
c
ce
le
Tightening Specification
un
pt
an
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itte
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Countersunk head bolt: 8 Nm without tightening angle (tighten
erm
ab
with the Wrench - Pump/Injector Long Reach - T10054- )
ility
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wit
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Flat head screws: 8 Nm + 90 (1/4 turn)
h re
ole,
spec
t to the co
rrectne
Mount the new transmission fluid pump cover -A-. Install the
s
stages.
s o
cial p
f in
Transmission does not have oil. New oil must now be added
form
mer
and adjust to the correct oil level. Refer to
atio
9 Transmission Fluid, page 113 .
om
n
c
i
or
n
Install the left front wheel housing liner. Refer to Body Ex
thi
e
terior; Rep. Gr. 66 ; Wheel Housing Liner; Overview - Front

t
sd
iva
Wheel Housing Liner . o

pr
cum
r
fo
en
ng

t.
yi Co
op
66 ; Noise Insulation; Overview - Noise Insulation . C py
t. rig
gh ht
yri
Install the wheel. Refer to Suspension, Wheels, Steering;
p by
co Vo
by lksw
Rep. Gr. 44 ; Wheels, Tires; Wheel Bolts, Tightening Speci Prote
cted AG.
agen
fications .
Refer to 1.1 Overview - Mechatronic, page 28
Transmission fluid pump to the transmission housing. Refer to
page 109 .
Transmission fluid pump cover to transmission housing. Refer
to
Fig. Tightening Specification and Sequence of the Trans
mission Fluid Pump Cover -A-. , page 30 .
8.3 Transmission Fluid Filter, Removing

and Installing
When to Change Transmission Fluid Filter
The transmission fluid filter does not need to be changed in every
case.
Do Not Replace the Filter If:
The transmission fluid cooler or its O-rings were replaced and
no coolants has gotten into the transmission fluid.
The selector shaft sealing ring was replaced.
The flange seal was replaced.
Leaking Mechatronic covers, DSG clutch or transmission flu
id pump were replaced.
The Filter Must be Replaced If:
The 60,000 km maintenance interval was reached.
Coolant has entered the fluid.
Metal shavings were found in the fluid.

The clutch is burned or has a mechanical fault.
Note
General repair instructions. Refer to

3 Repair Information, page 5 .
Caution


Filter - Transmission Fluid Filter
O-ring - Filter Housing
Removing
Remove the complete air filter housing:
Vehicles with a gasoline engine. Refer to Engine Mechan
ical, Fuel Injection and Ignition; Rep. Gr. 24 ; Air Filter; Air
Filter Housing, Removing and Installing
Vehicles with a diesel engine. Refer to Rep. Gr. 23 ; Air
Filter; Air Filter Housing, Removing and Installing
AG. Volkswagen AG d
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Remove the battery with the battery
hor tray. Refer to Electrical eo
ut
Equipment; Rep. Gr. 27 ; Battery;
ss a Battery Tray, Removing and ra
c
Installing .
ce
e
nl
pt
du
an
itte
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erm
ab
Note
ility
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wit
, is n
A little bit of fluid remains inside the filter. This will drain out
h re
once the filter is removed.

hole
spec
es, in part or in w
Lay some cloths down near the filter before removing it.
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

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.
Remove the filter housing and filter.
Remove O-ring from filter housing.
Installing
Install in the reverse order of removal while noting the following:
Clean thoroughly any areas on the transmission that get
stained with transmission fluid.
Install the transmission fluid filter with the collar on the bottom
-arrow-.
Install new O-ring on filter housing.
Install and tighten the filter housing.
Install in reverse order of removal.
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Check the fluid level and fill if necessary.
lksw
Refer
agenA to oes
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9.1 Transmission Fluid Level,bChecking,
yV
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a d ran
ise tee
Install the battery tray anduthe
tho battery. Refer to Electrical
r
or
Equipment; Rep. Gr. 27ss; Battery; Battery, Removing and In
a ac
stalling .
ce
le
un
pt
an
d
Install the complete air filter housing:

itte
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erm
ab
Gasoline engine. Refer to Rep. Gr. 24 ; Air Filter; Air Filter

ility
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wit
is n
h re

ole,
spec

t to the co
Filter housing. Refer to
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
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fo
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t.
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Prote AG.

9 Transmission Fluid
9.1 Transmission Fluid Level, Checking, page 113
9.2 Transmission Fluid, Draining and Filling, page 116
9.1 Transmission Fluid Level, Checking

Vehicle Diagnostic Tester
Shop Crane - Drip Tray - VAS6208-
Brake Line Tool Kit - Pipe Cutter - VAS6056/2-
Also for some fluid containers Oil Filler - Adapter 6 -
VAS6262/6-
Caution


AG. Volkswagen AG d
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Seal - Transmission Fluid Drain - and Check Plug Volksw
oes
not
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Note the Following Information: orise nte
eo
th
u ra
Use the ATF available as a replacement part. Refer
ss a
to the c
Parts Catalog.
ce
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nl
pt
du
an
It is necessary to use the Oil Filler - Adapter 6 - VAS6262/6-
itte
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erm
on some fluid containers.
ab
ility
ot p
It may be necessary to shorten the bleed pipe on the Adapter
wit
, is n
For Oil Filling - VAS6262A- . Refer to page 114 .
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Prote AG.
9. Transmission Fluid 113

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
tom on some fluid containers.
Dimension -a- = 210 mm
Note
Dimension -a- is measured starting from the shaft (the green sur
face) on the Adapter For Oil Filling - VAS6262A- .
AG. Volkswagen AG d
If dimension -a- is greater than 210 mm: lksw
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not
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Make a mark on the bleed pipe, dimension -a-, tand risecut it, with nte
ho eo
for example the Brake Line Tool Kit - Pipe Cutter
s au - ra
c
VAS6056/2- . s
ce
le
un
pt
Requirements
an
d
itte
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erm
ab
The vehicle is level and all hoist supports are the same height.
ility
ot p
wit
Noise insulation is removed. Refer to Body Exterior; Rep.
is n
h re
ole,
spec
Vehicle Diagnostic Tester is connected
t to the co
To begin working, the fluid temperature should not be higher
than 45 C (113 F).
rrectne
Test temperature: 35 to 45 C (95 to 113 F).
Checking
ss o
cial p
Vehicle Diagnostic Tester Connect and identify the vehicle in
f in
Guided Functions .
form
mer
atio
Select DSG transmission .
om
n
c
i
or
n
Select Check Fluid Level .
thi
te
sd
iva
o
pr
cum
r
fo
en
Note
ng
t.
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Cop py
t. rig
Let the transmission cool down if the fluid temperature is higher
gh ht
yri by
than 45 C (113 F).
cop Vo
by lksw
cted agen
Prote AG.
The engine is idling in neutral and the selector lever is in P.

Move the Used Oil Collection and Extraction Unit -
SMN372500- or a Drip Tray under the transmission near the
transmission fluid drain and check plug.

Always replace the seal for the drain plug -arrow-.wagen AG. Volkswagen AG doe
olks s no
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Note tho eo
au ra
c
ss
Even if the level of transmission fluid is too low, first a small
ce
e
nl
pt
du
amount of transmission fluid will flow out of the overflow tube,
an
itte
y li
because it fills during operation.
erm
ab
ility
ot p
wit
Let the excess fluid drain.
, is n
h re
hole
Install the drain plug with a new seal as soon as all the fluid
spec
has drained out (it starts to drip).
es, in part or in w
t to the co
If no transmission fluid comes out, then fill.
Adding
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

tight.
Fill 1.0 liters (1.05 quarts) of transmission fluid.
Remove the Adapter for Oil Filling - VAS6262A- at the quick-
release coupling and check it.
If ATF Flows Out of Adapter Hole:
Oil must not be topped off.
Let the excess oil drain.
As soon as the oil has run out (it begins to drip), remove the
Oil Filler - VAS6262A- and install .screw
Volkswawith
ge
new seal.
n AG n AG d
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If No Oil Flows Out of Hole:
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olks not
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ed
Add another liter
ho of transmission fluid.
ris nte
eo
t
au ra
c
ss
WARNING
ce
le
un
pt
an
d
itte
Too little or too much ATF will impair the transmission. y li

erm
ab
ility
ot p
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is n
h re
Insert the fluid drain plug and check plug with a new seal and
ole,
spec
tighten them.
t to the co
Transmission fluid drain- and check plug. Refer to
rrectne
9.2 Transmission Fluid, Draining and Filling

ss o
cial p
f i
Use the ATF available as a replacement part. Refer to the Parts

nform
Catalog.
mer
atio
m
Short Description
o
n
c
i
or
n thi
First, oil temperature is read out. If it is higher than 45 C (113

te
sd
a
F), then let the transmission to cool down.

iv
o
pr
cum
r
fo
Turn off the engine, remove the overflow pipe and drain any ATF.
en
ng
t.
yi
Install the overflow pipe and overfill the ATF.
Co
Cop py
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Start the engine and drain any excess oil until the oil level has
rig ht
py by
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reached the overflow tube. by c lksw
cted agen
Prote AG.
Shop Crane - Drip Tray - VAS6208-
Oil Filler - Adapter 6 - VAS6262/6-
Requirements
The engine is off.
The vehicle is level and all hoist supports are the same height.

Direct
olksw
Shift Gearbox - Edition 09.2015
AG. V agen AG
agen does
lksw not
Noise insulation is removed. Refer to Body db
y VExterior; Rep.
o gu
ara
Gr. 66 ; Noise Insulation; Overview - Noiserise Insulation . nte
tho eo
The selector level is in P. s au ra
c
s
ce
e
nl
Vehicle Diagnostic Tester is connected
pt
du
an
itte
y li
To begin working, the oil temperature should not be higher
erm
ab
than 45 C (113 F).
ility
ot p
wit
, is n
Procedure
h re
hole
spec
Follow the rules for clean working conditions when working on es, in part or in w
the transmission.
t to the co
Only use the ATF for the DSG transmission available as a
replacement part. Other oils can cause malfunctions or trans
rrectness of i
mission failure.
l purpos
WARNING
nform
ercia
Risk of injury due to hot transmission fluid.

m
at
om
ion
c
in t
or
Vehicle Diagnostic Tester connect and identify the vehicle in
his
te
Guided Functions .
a
do
priv
cum
or
Select DSG Transmission .

f
en
ng
t.
yi Co
op
Select Check Fluid Level . C py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Note
Prote AG.
Let the transmission cool down if the oil temperature is higher than
45 C (113 F).
WARNING

transmission.
Engine off - do not start!

The Used Oil Collection and Extraction Unit - SMN372500- or
Drip Tray is placed under the transmission.


A black plastic overflow tube is located
n AG.in
Vothis
lkswahole
gen A(with
G o 8 mm
lkswage
hex socket head). Its length determines the oil level in dthe
es ntrans
Vo ot g
mission. ed
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ra
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ra
a c
ss
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un
pt
an
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itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Remove the overflow pipe -arrow- and let the ATF drain.
nform
ercia
About 5 liters (5.28 qt) of oil will drain.

m
a
com
tion in
Install the overflow pipe and tighten it to the tightening speci
r
te o
fication.
thi
s
iva
do
r

rp
cum
fo

en
ng
t.
yi
page 110 .
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
tight.

Fill 5.5 liters (5.8 qts) of transmission fluid.
To change containers, close the shut-off valve or hold the Oil
Filler - VAS6262A- higher than the transmission.

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. Then move the se
lector lever back into P.
Do not turn off the engine.
Check the ATF level and fill if necessary. Refer to
Overflow Pipe. Refer to
AG. Volkswagen AG d
agen oes
olksw not
byV gu
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ed
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aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

10 Special Tools
Special tools and workshop

equipment required
Engine Support Bridge -
10-222A-
Engine Support 29 -
10-222A/29-
Engine Support 18 -
10-222A/18-
Engine/Gearbox Support
Shackle (2 pc.) - 10-222A/
12- (quantity 2)
Transmission Support -
Pins 29 - 3282/29-
3282-
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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Engine and Gearbox Jack -

VAS6931-
Mounting Plate 42A -
3282/42A-
Hose Clamps - Up To
25mm - 3094-
Engine Bung Set -
VAS6122-
Insert Tool - 18mm -
T10179-
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10. Special Tools 121

Torque Wrench 5-50Nm -

VAG1331-
Used Oil Collection and Ex
traction Unit - SMN372500-
Shop Crane - Drip Tray -
VAS6208-
Oil Filler - Adapter 2 -
VAS6262/2-
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Wrench - Pump/Injector Long Reach - T10054-

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Socket - Xzn 14 - T10061- AG. Volkswagen AG d

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Puller - Crankshaft/Power Steering Seal - T20143-
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Engine Support - Supplement Kit Spindle - T40093/3- (quan
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Hose Clip Pliers - VAG1275A-
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Engine And Transmission Holder - VAS6095-

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Shop Crane - VAS6100-

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Also for some oil containers Oil Filler - Adapter 6 - VAS6262/6-
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Transmission Support - VW353-
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Press Piece - Shift Rod/Alternator - VW423-

Engine Sling - 2024A-
Transmission Support Jig - 3336-
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35 Gears and Shafts

1 Gears and Shafts, Disassembling
and Assembling
No Repairs to Gears and Shafts
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1. Gears and Shafts, Disassembling and Assembling 127

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1.2 Left Seal, Replacing, page 128 .
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Do not remove all the bolts in the left and right flange shafts at the same time. If the differential bevel gears
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6.1 Overview - Trans
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5 - Selector Lever
6 - Gearshift Shaft Seal
Replacing. Refer to
2.9 Selector Shaft
Seal, Replacing,
page 69 .
7 - Seal
For the left flange shaft
Replacing. Refer to
1.2 Left Seal, Replac
ing, page 128 .
8 - Left Flange Shaft
9 - Bolt
30 Nm
1.2 Left Seal, Replacing

Slide Hammer Set - VW771-
128 Rep. Gr.39 - Final Drive, Differential

Seal Installer - Flange Shaft - 3305-

Socket And Extended Bit - T10107A- or AG. Volkswagen AG d
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Observe. Refer to 3 Repair Information, page 5 .
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Lift the vehicle, all four take-up points of lifting platform at same
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Remove the lower section of the left front wheel housing liner.
Remove the left drive axle. Refer to Suspension, Wheels,
Steering; Rep. Gr. 40 ; Drive Axle; Drive Axle, Removing and
Installing .
Remove the left transmission flange shaft using the Socket

And Extended Bit - T10107A- .
The bolt has a 6 mm inner hex socket. The bolt can also be re
moved and installed using Long Hex Socket - VAG1669- .
1. Seals 129
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Direct Shift Gearbox - Edition 09.2015 s aut ra
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pt
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with Sealing Grease - G 052 128- .

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.
Insert the flange shaft and secure it with bolts.

Install the left drive axle. Refer to Suspension, Wheels,
Steering; Rep. Gr. 40 ; Drive Axle; Drive Axle, Removing and
Installing .
Install the left front wheel housing liner. Refer to Body Ex
terior; Rep. Gr. 66 ; Wheel Housing Liner; Overview - Front
Wheel Housing Liner .
Attach the left front wheel. Refer to Suspension, Wheels,
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Steering; Rep. Gr. 44 ; Wheels and Tires;swaWheel,
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Install the noise insulation. sRefer to Body Exterior; Rep. Gr.
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66 ; Noise Insulation; Overview - Noise Insulation .

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Seal Installer - Axle Flange - 3158-
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Socket And Extended Bit - T10107A-
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General repair instructions. Refer to
3 Repair Information, page 5 .

1. Seals 131
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-.
Remove the right drive axle from the transmission. Refer to
Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axle; Drive
Axle, Removing and Installing .
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Remove the nut from the bracket for the Right Front Level
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Fasten the right ball joint -2- on the control arm -1- with a nut
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Secure the right drive axle to the suspension strut using a

Tensioning Strap - T10038- .
Do not damage the surface of the shaft.
Remove the right transmission flange shaft using the Socket

And Extended Bit - T10107A- .
The bolt has a 6 mm inner hex socket. The bolt can also be re
moved and installed using Long Hex Socket - VAG1669- .
To remove and install the flange shaft, install 2 bolts into the
flange and counterhold it using a pry bar.
AG. Volkswagen AG d
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1. Seals 133
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.
Insert the flange shaft and secure it with bolts.

Install the ball joint. Refer to Suspension, Wheels, Steering;
Rep. Gr. 40 ; Lower Control Arm and Ball Joint; Overview -
Lower Control Arm and Ball Joint .
Fasten the drive axle to the flange shaft. Refer to Suspen
sion, Wheels, Steering; Rep. Gr. 40 ; Drive Axle; Drive Axle,
Install the heat shield over the right drive axle, if equipped.
Refer to Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive
Axle; Drive Axle, Removing and Installing .
AG. Volkswagen AG d
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Check the fluid level and fill if necessary. Refer to Volksw not
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9.1 Transmission Fluid Level, Checking, page 113 . d by ara
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Install the noise insulation. Refer to Body Exterior; Rep.auGr.
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66 ; Noise Insulation; Overview - Noise Insulation . s
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Flange shaft to transmission. Refer to
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2 Special Tools
AG. Volkswagen AG d
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Tensioning Strap - T10038- s aut ra
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Socket And Extended Bit - T10107A-
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Slide Hammer Set - VW771-

Seal Installer - Axle Flange - 3158-
Seal Installer - Flange Shaft - 3305-
AG. Volkswagen AG d
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3 Revision History
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3. Revision History 137

Cautions & Warnings
Please read these WARNINGS and CAUTIONS before proceeding with maintenance
and repair work. You must answer that you have read and you understand these
WARNINGS and CAUTIONS before you will be allowed to view this information.
= If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we
AG. Volkswagen AG d
suggest you leave such repairs to an authorized Volkswagen retailer or sw agen qualified shop.
other Weoesespecially urge
k not
you to consult an authorized Volkswagen retailer before beginning y Vol
repairs on any vehicle that may still
gu be covered
d b ara
e nte
ris
wholly or in part by any of the extensive warranties issued byhoVolkswagen. e t or
au ac
ss
= Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical
ce
le
un
pt
system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.
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= Volkswagen is constantly improving its vehicles and sometimes these changes, both in parts and specifications, pe
ility
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are made applicable to earlier models. Therefore, part numbers listed in this manual are for reference only. Always
wit
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check with your authorized Volkswagen retailer parts department for the latest information.
hole
spec
es, in part or in w
= Any time the battery has been disconnected on an automatic transmission vehicle, it will be necessary to
t to the co
reestablish Transmission Control Module (TCM) basic settings using the VAG 1551 Scan Tool (ST).
= Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose. Do not support
rrectness of i
a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a
l purpos
vehicle that is supported solely by a jack. Never work under the vehicle while the engine is running.
nform
ercia
= For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before disconnecting the
battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and
m
a
com
t
become inoperable, even if the correct code is used in a later attempt.
ion in
r
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thi
= If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to
s
iva
do
keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
r
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starting the vehicle while you are under it.
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= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
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others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from cop Vo
by lksw
being fully alert. cted agen
Prote AG.
= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
= Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear
goggles, gloves and other protective clothing whenever the job requires working with harmful substances.
= Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near
machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe
injury could result.
= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used
only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with
new parts where indicated, and any other time it is deemed necessary by inspection.
Page 1 of 3
2002 Volkswagen of America, Inc.
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.
Version 1.0
Cautions & Warnings
= Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the vehicle.
Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled
fuel or oil.
= Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by
grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust.
Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may result in death.
= Finger rings should be removed so that they cannot cause electrical shorts, get caught in running machinery, or be
crushed by heavy parts.
= Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the
instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only
lkswagen AG
AG. VoMakeshift
replacement parts meeting Volkswagen specifications.
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agen tools,
does parts and procedures will not make good
ol not
repairs. by V gu
a
ed ran
oris tee
th or
= Catch draining fuel, oil or suitable containers. Do not use brakes aufluid in
beverage containers that empty food acor
s
might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at
ce
e
nl
pt
once, but do not store the oily rags, which can ignite and burn spontaneously.
du
an
itte
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= Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten
ility
ot p
fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque
wit
, is n
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= Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is
t to the co
ignited, it will ignite gas trapped in the cells and cause the battery to explode.
= Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of
rrectness of i
the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that
l purpos
govern the disposal of wastes.
= The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should be nform
ercia
serviced only by trained automotive service technicians using approved refrigerant recovery/recycling equipment,
m
at
trained in related safety precautions, and familiar with regulations governing the discharging and disposal of
om
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c
automotive chemical refrigerants.

in t
or
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ate
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= Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect the battery
p
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negative terminal (ground strap) and the ABS control module connector.
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Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase t. rig
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system pressure and may cause the system to burst. cop
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= When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission
Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these
components is not separately fused, disconnect the control module connector(s).
= Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that
automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device.
Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal
injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians
should test, disassemble or service the airbag system.
Page 2 of 3
Version 1.0
Cautions & Warnings
= Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 16.5 volts at the
battery with the boosting cables attached. Wait at least one minute before boosting the battery a second time.
= Never use a test light to conduct electrical tests of the airbag system. The system must only be tested by trained
Volkswagen Service technicians using the VAG 1551 Scan Tool (ST) or an approved equivalent. The airbag unit
must never be electrically tested while it is not installed in the vehicle.
= Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been
inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair
area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the
tire from the rim before attempting any repair.
= When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or lap while the
vehicle is in motion. Objects between you and the airbag can increase the risk of injury in an accident.
I have read and I understand these Cautions and Warnings.
AG. Volkswagen AG d
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Page 3 of 3
Version 1.0

D4B804111B4-Direct Shift Gearbox

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Service

Service Department. Technical Information

All rights reserved.

Copyright 2016 Volkswagen AG, Wolfsburg D4B804111B4

00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 Clutch End Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.3 DSG Clutch, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1.1 Overview - Mechatronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.1 Overview - Selector Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

2.3 Selector Lever Handle, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

2.4 Button in Handle, Moving Into Installation Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

2.5 Selector Mechanism, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

2.6 Selector Lever Cable, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

2.7 Gearshift Mechanism, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

2.8 Selector Lever Cable, Checking and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

2.9 Selector Shaft Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

6 Transmission, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

1 Gears and Shafts, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

39 - Final Drive, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

001 - Serial Number

2 Rep. Gr.00 - General, Technical Data

2.1 General Safety Precautions

tronic Components, Observe the Following:

Risk of damaging electronic components when disconnecting nform

Complete the steps for disconnecting the battery.

Always turn off the ignition before disconnecting the bat

When Working on Vehicles with Start/Stop, Note the Following:

Danger of injury through automatic motor starting with vehicles

2.3 Safety Precautions when Tow Starting

Danger of causing damage to the transmission.

2.4 Safety Precautions during Road Test

with Testing Equipment

If Testers and Measuring Equipment Must Be Used during a Test

secured testing equipment.

Operating testing equipment while driving is a distraction.

Testing equipment that is not secured properly increases

the risk of personal injury.

strap and have a second person in the rear seat operate

4 Rep. Gr.00 - General, Technical Data

3.1 General Information

ed to the braking effect of the engine.

Direct gear selection by way of the Tiptronic function permits

utilization of engine braking action with a specific gear engag

ed, for example, on a downhill gradient with a trailer.

3.2 Clean Working Conditions

Seal all open lines and connections immediately with clean

plugs or caps from the Engine Bung Set - VAS6122- .

Always make sure that no dirt enters an open transmission.

Only install clean components. Install replacement parts im

mediately after removing them from their packaging.

Cover all opened components carefully if it necessary to per

Protect the disconnected connectors from dirt and moisture

3.3 General Repair Information

Special Tools and Equipment

transmission. Any dirt that enters can cause transmission failure,

mission cover is removed or if there is no transmission fluid

inside the transmission.

Replace damaged or stretched circlips.

The circlips must fit completely inside the groove.

Transmission Fluid, Environmental and Disposal Regulations.

The quality of transmission fluid is crucial to transmission function.

6 Rep. Gr.00 - General, Technical Data

Fluid Drain and Check Plug