Service: Crafter 2006

Service
Workshop Manual
Crafter 2006 ➤
Shiftmatic automated gearbox 0B8
Edition 09.2012
AG. Volkswagen AG d
agen oes
olksw not
V gu
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
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c
Service Department. Technical Information
lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
Service
d b ara
rise nte
tho eo
au ra
ss c
ce
le
List of Workshop Manual Repair Groups
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
Repair Group
t to the co
00 - Technical data
30 - Clutch
rrectne
34 - Controls, housing
ss
35 - Gears, shafts
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
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 © 2015 Volkswagen AG, Wolfsburg K0059030320

Crafter 2006 ➤
Shiftmatic automated gearbox 0B8 - Edition 09.2012
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 General repair instructions for gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Gaskets, seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 Locking devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.4 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.5 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.6 Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.7 Synchro-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.8 Gear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
AG. Volkswagen
3.1 Allocation of gearbox to engine, gear ratios ksw
a.g.e.n . . . . . . . . . . .AG
. .do. e.s.n . . . . . . . . . . . . . . . . . 4
ol ot g
yV ua
db
30 - Clutch . . . . . . . . . . . . . . . . . . . .ho.ris. . . . .
e ............. . . . . . . . .ra.nte.e. . . . ..... 5
t o
1 au
Clutch operation . . . . . . . . .ss. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . r.a.c . .
...... 5
1.1 Removing and installing clutch slave cylinder together with release bearing . . . . . . . . . . . . 5
ce
le
un
pt
1.2 Removing and installing clutch travel sender G162 for slave cylinder with release bearing
an
d
itte
y li
........................................................................ 6
rm
ab
pe
ility
2 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ot
wit
, is n
2.1 Assembly overview - clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
h re
hole
2.2 Removing and installing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
spec
2.3 Resetting adjusting ring of self-adjusting pressure plate . . . . . . . . . . . . . . . . . . . . . . . . . . 10
es, in part or in w
t to the co
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
rrectness of i
1.1 Overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
l purpos
1.2 Removing and installing selector lever E313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.3 Removing and installing gearbox hydraulic pressure sender G270 . . . . . . . . . . . . . . . . . . 16
nform
ercia
1.4 Removing and installing pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

m
1.5 Disposing of pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a 18

com
tio
1.6 Removing and installing gearbox speed sender G38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
n in
r
te o
thi
1.7 Removing and installing gear detection sensor G604 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

s
iva
do
1.8 Removing and installing electronic manual gearbox control unit J514 . . . . . . . . . . . . . . . . 23
r
rp
cum
fo
1.9 Table - adapting components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

en
ng
t.
yi
1.10 Removing and installing pan for hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Co
Cop py
.
1.11 Removing and installing hydraulic control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
ht rig
rig ht
py by
1.12 Removing and installing gearbox hydraulic pressure sender V387 . . . . . . . . . . . . . . . . . . 34
co Vo
by lksw
cted agen
1.13 Checking hydraulic fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prote
35
AG.
1.14 Draining and filling hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

2 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.1 Specified torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.2 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.3 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.1 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4 Gearbox housing, clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.1 Renewing sealing cover in gearbox housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.2 Removing and installing gearbox breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5 Gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.1 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Contents i
Crafter 2006 ➤
5.2 Draining and filling gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.1 Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.1 Renewing output shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
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
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ii Contents
Crafter 2006 ➤
00 – Technical data
1 Identification
(VRL005142; Edition 09.2012)
⇒ “1.1 Gearbox identification”, page 1
1.1 Gearbox identification

n AG. Volkswagen A
The Shiftmatic automatedolks
wmanual
age gearbox 0B8 isesinstalled
G do
not in the
Crafter 2006 ► in conjunction
d by V with a 5-cylinder diesel gengine.
uar e an
ris te
The gearbox ucode
tho is stated on the data sticker ⇒ Maintenance
eo ;
ra
Booklet 10.2
s .
s a c
ce
le
un
Only the part number appears on the gearbox.
pt
an
d
itte
y li
Part number -arrow-
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Identification 1
Crafter 2006 ➤
2 Repair instructions
⇒ “2.1 General repair instructions for gearboxes”, page 2
⇒ “2.2 Gaskets, seals”, page 2
⇒ “2.3 Locking devices”, page 3
⇒ “2.4 Nuts and bolts”, page 3
⇒ “2.5 Bearings”, page 3
⇒ “2.6 Shims”, page 3
⇒ “2.7 Synchro-rings”, page 3
⇒ “2.8 Gear wheels”, page 3
2.1 General repair instructions for gearbox‐

es
To ensure flawless and successful gearbox repairs, the greatest
care and cleanliness as well as the use of good and proper tools
are essential. Of course, the basic rules for safety also apply dur‐
ing repair work.
A number of generally applicable instructions for the various re‐
pair procedures which were previously repeated at numerous
places in the workshop manual are summarised here. They apply
to this workshop manual.
♦ During installation, ensure that the dowel sleeves between the
engine and gearbox are correctly located.
♦ When exchanging a Shiftmatic automated manual gearbox, fill
with gear oil to lower edge of filler hole and check hydraulic
fluid level.
♦ Gearbox capacity ⇒ page 51 .
♦ Quantity of hydraulic fluid ⇒ page 35 .
AG. Volkswagen
♦ Gear oil specification ⇒ Maintenance
lksw
agen ; Booklet
AG do
e10.2
sn o ot g
yV ua
db
2.2 Gaskets, seals
ris
e ran
tee
tho or
au a
♦ Thoroughly
ss clean parting surfaces and apply sealing paste - c
AMV 188 200 03- .
ce
e
nl
pt
du
an
itte
♦ Apply sealing paste uniformly but not too thick.

y li
erm
ab
♦ Renew O-rings.
ility
ot p
wit
, is n
♦ Radial oil seals.

h re
hole
spec
Before installing radial oil seals:

es, in part or in w
t to the co
Lightly oil outer diameter and half-fill space between sealing lips
-arrow- with grease -G 052 128 A1- .
After installation:
rrectness of i
♦ Check oil level and top up if necessary ⇒ page 51 .

l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
2
by lksw
cted agen
Rep. gr.00 - Technical data Prote AG.
Crafter 2006 ➤
olkswagen AG
en AG. V
2.3 Locking
yV
olkdevices
swa
g
does
not
gu
d b ara
e
♦ Renew retaining
horis rings. nte
eo
ut ra
a
♦ Do not overstretch
ss retaining rings. c
ce
le
un
♦ Retaining rings must locate properly in grooves.
pt
an
d
itte
y li
♦ Renew spring pins. Installation position: slot longitudinal to line
erm
ab
of force.
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
2.4 Nuts and bolts
ss
♦ Loosen and tighten securing bolts and nuts for covers and
o
cial p
f
housings diagonally.
inform
mer
♦ Do not cant especially delicate parts, such as clutch pressure
atio
m
plates. Loosen and tighten bolts and nuts in stages in a diag‐

o
n
c
onal sequence.
i
or
n thi
te
sd
a
♦ Specified torques settings are specified for unoiled bolts and

iv
o
pr
c
nuts. um
r
fo
en
ng
t.
♦ Always renew self-locking bolts and nuts.
yi Co
Cop py
t. rig
2.5 Bearings
gh ht
pyri by
Vo
co lksw
by
cted agen
♦ Install needle bearings with lettered side towards fitting tool. Prote AG.
2.6 Shims
♦ Measure shims at several points with a micrometer. The var‐
ious thicknesses make it possible to achieve the exact shim
thickness required.
♦ Check for burrs and damage.
♦ Install only flawless shims.
2.7 Synchro-rings
♦ Do not interchange synchro-rings.
♦ When reusing synchro-rings, always fit to the same gear.
♦ Check for wear and renew if necessary.
♦ Moisten with gear oil before installing.
2.8 Gear wheels

♦ Before installing, clean and heat on a hot plate to approx.
100° C.
♦ The temperature can be checked with thermometer -V.A.G
1558- , ignition tester -V.A.G 1767- or diesel tester -V.A.G
1743- .
2. Repair instructions 3
Crafter 2006 ➤
3 Technical data AG. Volkswagen AG d

agen oes
ksw
⇒ “3.1 Allocation of gearbox to engine, gear ratios”, page 4 by V ol not
gu
ara
ed
is nte
3.1 Allocation of gearbox to engine, gear ra‐ or eo
h
aut ra
tios ss c
ce
e
nl
pt
du
an
Shiftmatic automa‐ 0B8
itte
y li
erm
ted gearbox
ab
ility
ot p
Identification code HRF
wit
, is n
h re
Allocation Model Crafter
hole
spec
Engine code: BJK 2.5 I - 80 kW
es, in part or in w
t to the co
Engine code: BJL 2.5 I - 100 kW
Ratio:
rrectness of i
Constant mesh 3925 ik = 1.56
gears
l purpos
1st gear 3925x4514 i1 = 5.014

2nd gear 3925x4927 i2 = 2.831
nf
ercia
orm
3rd gear 3925x3934 i3 = 1.789
m
atio
om
n in
4th gear
c
3925x3341 i4 = 1.256
or
thi
te
sd
5th gear i5 = 1.0
iva
o
r
rp
cu
6th gear 3925x2447 i6 = 0.797
o
m
f
en
ng
t.
yi Co
Reverse gear 3925x2323x4114 iR = 4.569 t. Cop py
rig
gh ht
yri
Speedometer electronic p by
o Vo
by c lksw
cted
Capacity Manual gearbox 1.5 l
agen
Prote AG.
Hydraulic unit 0.5 l

Specification ⇒ Maintenance ; Booklet 10.2
Clutch operation Electronic/hydraulic
Clutch plate ∅ 240 mm
4 Rep. gr.00 - Technical data

Crafter 2006 ➤
30 – Clutch
1 Clutch operation
⇒ “1.1 Removing and installing clutch slave cylinder together with
release bearing”, page 5
⇒ “1.2 Removing and installing clutch travel sender G162 for slave
cylinder with release bearing”, page 6
n AG. Volkswagen A
1.1 RemovingVoand lksw installing clutch eslave
age G do
s no
t gu
cylinder
orised together
by
with release bearing ara
nte
h eo
ut
Special tools and
ss workshop equipment required
a ra
c
ce
e
♦ Torque wrench -V.A.G 1331-

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
nf
ercia
Removing
orm
m
– Remove Shiftmatic automated manual gearbox ⇒ page 41 .

atio
om
n in
c
– Separate connector for clutch travel sender -G162- -1-.

or
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Pry securing clip -1- out of hydraulic line using a small screw‐
driver.
– Pull out hydraulic line.
Note
To prevent hydraulic fluid from escaping, seal the pulled-off hy‐

draulic line using, for example, the sealing cap from the brake
bleeder valve.
1. Clutch operation 5
Crafter 2006 ➤
– Remove bolts -1- and remove slave cylinder with release bear‐
ing -2-.
Note
♦ Do not apply compressed air to removed slave cylinder with

release bearing because it can be pressed apart and de‐
stroyed. . Volkswag AG en AG
agen does
♦ The slave cylinder with release bearing is a ysingle
Vol
ksw component. not
gu
b ara
ed nte
oris
Installing au
th eo
ra
ss c
Install in reverse order of removal, observing the following:
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
In spite of a bleeder valve on the slave cylinder with release bear‐
h re
hole
ing, no bleeding should be carried out because the entire hy‐
spec
draulic system for the gearbox including the clutch is self-
es, in part or in w
bleeding.
t to the co
Specified torques
rrectness of i
♦ ⇒ “2.1 Specified torques for gearbox”, page 41
l purpos
Component Specified torque
nf
ercia
Securing bolts for slave cylin‐ 9 Nm
or
der with clutch release bearing
m
m
atio
om
n in
– Check hydraulic fluid level and top up if necessary
or c
⇒ page 35 .
thi
te
sd
iva
– Carry out the function “Learn clutch release point” ⇒ Vehicle o

r
rp
cu
o
diagnostic tester.
f
en
ng
t.
yi Co
Cop py
1.2 Removing and installing clutch travel

t. rig
gh ht
pyri by
Vo
o
sender -G162- for slave cylinder with re‐
c by lksw
cted agen
Prote AG.
lease bearing
Special tools and workshop equipment required
6 Rep. gr.30 - Clutch

Crafter 2006 ➤
Removing
– Separate connector for clutch travel sender -G162- -1-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
– Release wiring for clutch travel sender -G162- -1-.
y li
rm
ab
pe
– Remove securing nuts -2- and pull off clutch travel sender -
ility
ot
G162- .
wit
, is n
h re
hole
Installing
spec
es, in part or in w
t to the co
– Carry out the function “Learn clutch release point” ⇒ Vehicle
diagnostic tester.
rrectness of i
Specified torques
l purpos
nform
ercia

m
Securing bolts for clutch travel 3 Nm
a
com
tio
sender -G162-
n in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Clutch operation 7
Crafter 2006 ➤
2 Clutch
⇒ “2.1 Assembly overview - clutch”, page 8
⇒ “2.2 Removing and installing clutch”, page 8
⇒ “2.3 Resetting adjusting ring of self-adjusting pressure plate”,
page 10 agen
AG. Volkswagen AG d
oes
olksw not
V
2.1 Assembly overview - clutch by gu
d ara
ise nte
or eo
h
aut ra
ss c
1 - Flywheel
ce
e
nl
pt
du
❑ Ensure that centring
an
itte
y li
pins fit tightly
erm
ab
ility
❑ Contact surfaces for ot p
wit
clutch lining must be
, is n
h re
free of grooves, oil and
hole
spec
grease
es, in part or in w
❑ Removing and installing
t to the co
⇒ Cylinder block (gear‐
box end); Rep. gr. 13 ;
Removing and installing
rrectness of i
flywheel .
l purpos
2 - Clutch plate
nf
ercia
Note
orm
m
atio
m
Installation position of clutch plate:

o
n in
c
lettering “Getriebsseite” must face

or
thi
e
gearbox.
t
sd
iva
o
r
rp
cu
❑ Centring ⇒ page 10
o
m
f
en
ng
t.
yi
❑ Lightly grease splines
Co
Cop py
t. rig
3 - Pressure plate
gh ht
pyri by
Vo
o
by c
lksw
cted agen
Prote
⇒ page 8 .
AG.
❑ Check ends of dia‐

phragm spring
⇒ page 10
4 - Bolt
❑ Loosen or tighten diag‐
onally and in steps
❑ 22 Nm
2.2 Removing and installing clutch


Crafter 2006 ➤
♦ Centring mandrel -3434-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
♦ Counterhold tooluth-3386-
o eo
ra
s a c
s
ce
le
un
pt
an
d
itte
y li
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
Note
nform
ercia
If vehicle is manoeuvred for a longer time with a slipping clutch,

m
the temperature of the clutch will rise. There is a two-stage clutch-

com
tion in
protection function to warn of critical temperatures. Above a cal‐

r
te o
culated clutch temperature of 250 °C, the clutch will be closed

thi
s
iva
faster when the vehicle is driven off. If the calculated clutch tem‐
do
r
rp
perature exceeds 300 °C, the driver is warned by a hard jolt from
um
fo
the clutch when driving off. If the drive ignores this warning and
en
ng
t.
yi Co
continues to overload the clutch, the clutch will be destroyed. t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Clutch 9
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
Crafter 2006 ➤ orise nte
eo
h
Shiftmatic automated gearbox
s aut
0B8 - Edition 09.2012 ra
c
s
ce
e
nl
pt
du
an
itte
y li
Centring clutch plate and removing and installing pressure plate
erm
ab
ility
ot p
– Fit counterhold tool -3386- .
wit
, is n
h re
– Loosen or tighten bolts diagonally in stages. hole
spec
Installing
es, in part or in w
t to the co
rrectness of i
Note
l purpos
♦ Pressure plate contact surface and clutch plate lining must

make full contact with flywheel.
nform
ercia
♦ Tighten securing bolts diagonally and evenly to prevent dam‐

m
at
om
i
age to pressure plate centring hole and flywheel centring pins.
on
c
in t
or
♦ Renew clutch plates and pressure plates with damaged or
his
ate
loose rivets.
do
priv
cum
or
♦ Select clutch plate and pressure plate according to ⇒ Elec‐

f
en
ng
t.
yi
tronic parts catalogue “ETKA” and engine codes.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
Checking ends of diaphragm spring -arrows-
by
cted agen
Prote AG.
• Wear up to half the thickness of the diaphragm spring is per‐

mitted.
– Carry out the functions “Learn clutch release point” and “Learn
gearbox shift position” ⇒ Vehicle diagnostic tester.
Specified torques
♦ ⇒ “2.1 Assembly overview - clutch”, page 8
2.3 Resetting adjusting ring of self-adjusting

pressure plate
♦ Press tool -VW 412-

Crafter 2006 ➤
♦ Thrust pad -3062-
Note
♦ Only when a new clutch plate is installed with a used self-ad‐

justing pressure plate should the adjusting ring be reset to
stop.
♦ If the adjusting ring is not reset, clutch pressure will be reduced
and cause an increase in clutch plate wear.
♦ If the clutch plate is not renewed, the adjusting ring need not
be reset. New pressure plates are already adjusted.
– Centre thrust pad -3062- in middle of pressure plate.
AG. Volkswagen AG d
agen oes
Note olksw not
byV gu
ara
ed
ris nte
Do not use force
ut when performing the following work:
ho eo
ra
s a c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Clutch 11
AG. Volkswagen AG d
agen oes
ksw
Crafter 2006 ➤ by
Vol not
gu
d ara
Shiftmatic automated gearbox 0B8 - Edition
orise 09.2012 nte
h eo
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
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Apply two screwdrivers to forks on adjusting ring.

– Press down on pressure plate with press until adjusting ring
can just be moved.
– Using the two screwdrivers, turn back adjusting ring evenly in
-direction of arrow- to stop.
– Hold adjusting ring against stop and reduce pressure exerted
by the press so that adjusting ring is held in this position.

Crafter 2006 ➤
34 – Controls, housing
1 Selector mechanism
⇒ “1.1 Overview - selector mechanism”, page 13
⇒ “1.2 Removing and installing selector lever E313 ”, page 14
⇒ “1.3 Removing and installing gearbox hydraulic pressure send‐
er G270 ”, page 16
⇒ “1.4 Removing and installing pressure accumulator”,
page 16
⇒ “1.5 Disposing of pressure accumulator”, page 18
⇒ “1.6 Removing and installing gearbox speed sender G38 ”,
page 18 n AG. Volkswagen A
ge G do
swa es
⇒ “1.7 Removing
by
Vol and installing gear detectionotsensor
k n
gu
ara
G604 ”,
page 19 rised
nte
tho eo
⇒ “1.8
ss
aRemoving
u
and installing electronic manual gearbox
r a control
c
unit J514 ”, page 23 ce
le
un
pt
an
⇒ “1.9 Table - adapting components”, page 23
d
itte
y li
rm
ab
⇒ “1.10 Removing and installing pan for hydraulic fluid”,
pe
ility
page 24
ot
wit
, is n
h re
⇒ “1.11 Removing and installing hydraulic control unit”,

hole
spec
page 26
es, in part or in w
t to the co
⇒ “1.12 Removing and installing gearbox hydraulic pressure

sender V387 ”, page 34
⇒ “1.13 Checking hydraulic fluid level”, page 35
rrectness of i
⇒ “1.14 Draining and filling hydraulic fluid”, page 37

l purpos
1.1 Overview - selector mechanism

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Selector mechanism 13
Crafter 2006 ➤
1 - Selector lever -E313-

❑ Removing and installing AG. Volkswagen AG d
⇒ page 13 . agen oes
olksw not
V gu
by ara
2 - Gearbox speed sender - rised
nte
G38- aut
ho eo
ra
s c
❑ Removing and installing s
ce
le
⇒ page 18 .
un
pt
an
d
itte
y li
3 - Gearbox breather
erm
ab
ility
ot p
wit
⇒ page 50 .
is n
h re
ole,
4 - Gear detection sensor -
spec
G604-
t to the co
⇒ page 19 .
rrectne
5 - Angled magnet
s
⇒ page 26 .
s o
cial p
f
6 - Hydraulic pump for gearbox
inform
-V387-
mer
atio
om
n
⇒ page 34 .
c
i
or
n thi
te
7 - Pressure accumulator
sd
iva
o
pr
c
um
r
fo
en
ng
⇒ page 16 . yi
t.
Co
op
❑ Remove and install with
C py
t. rig
gh
gearbox hydraulic pres‐
ht
pyri by
Vo
sure sender -G270-
o
by c lksw
cted agen
⇒ page 16 Prote AG.
8 - Diagnostic connection
❑ Connecting
⇒ page 23
9 - Hydraulic control unit
❑ Removing and installing ⇒ page 26 .
10 - Pan for hydraulic fluid
11 - Electronic manual gearbox control unit -J514-
12 - Wiring harness
13 - Slave cylinder with clutch release bearing
❑ With clutch travel sender -G162-
1.2 Removing and installing selector lever -

E313-
14 Rep. gr.34 - Controls, housing

Crafter 2006 ➤
Removing
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting battery .
Gearbox must be in neutral.
– Release clips from selector lever cover -arrows- and pull them
upwards.
– Remove centre console ⇒ General body repairs, interior; Rep.
gr. 70 ; Trim, insulation .
AG. Volkswagen AG d
agen oes
olksw not
yV gu
– Remove securing isbolts
ed
b -A-. ara
nte
or e
h
– Separate wiring
s aut harness connection and remove selector lev‐ or a
c
er -E313- . s
ce
le
un
pt
Installing
an
d
itte
y li
rm
ab

pe
ility
ot
– Carry out the function “Learn gearbox shift position” ⇒ Vehicle

wit
, is n
h re
diagnostic tester.
hole
spec
Specified torques
es, in part or in w
t to the co
♦ Battery; Disconnecting and connecting battery ⇒ Rep. gr. 27 ;

Disconnecting and connecting battery
rrectness of i
♦ Dash panel; Removing and installing dash panel ⇒ Rep. gr.

70 ; Dash panel
l purpos

nform
ercia
Selector lever -E313- to dash 20 Nm

panel
m
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.
olkswagen AG
wag en AG. V
Crafter 2006 ➤ olks
does
not
yV gu
Shiftmatic automated
sed gearbox 0B8 - Edition 09.2012
b ara
n ri tee
ho
ut or
1.3 Removing and installing gearbox hy‐
a ac
ss
ce
e
draulic pressure sender -G270-
nl
pt
du
an
itte
y li
Removing
erm
ab
ility
ot p
– Carry out the function “Relieving pressure, gearbox hydraul‐
wit
, is n
ics” ⇒ Vehicle diagnostic tester.
h re
hole
spec
– Remove securing bolts -2- and pull cover -1- downwards out
es, in part or in w
of guide -arrow-.
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
– Separate connector -1-.
atio
om
n in
or c
thi
te
sd
Note
iva
o
r
rp
cu
o
m
f
♦ Separating connector -1- will prevent unintentional starting of
en
ng
t.
yi Co
hydraulic pump for gearbox -V387- . ht. Cop py
rig
rig ht
♦ Connector -2- is not to be separated. py by
co Vo
by lksw
cted agen
Prote AG.
– Pull off connector -1- and screw out gearbox hydraulic pres‐
sure sender -G270- -2-.
Installing
– Before reconnecting separated connector -1- for hydraulic

pump for gearbox -V387- , check hydraulic fluid level and top
up as required ⇒ page 35 .
Specified torque
Gearbox hydraulic pressure 3 Nm
sender -G270-
1.4 Removing and installing pressure accu‐

mulator

Crafter 2006 ➤
Removing
– Remove securing bolts -2- and pull cover -1- downwards off
guide -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d

itte
y li
erm
ab
ility
ot p
wit
is n
Note
h re
ole,
spec
hydraulic pump for gearbox -V387- .

t to the co
♦ Connector -2- is not to be separated.

rrectness o
cial p
f inform
– Unbolt pressure line -1- from pressure accumulator -7-.

mer
atio
m
– Pull breather hose -2- off breather valve -4-.

o
n
c
i
or
n thi
– Turn breather valve -4- about 45° to the right and pull it out.
te
sd
iva
o
pr
– Separate connector -8- from gearbox hydraulic pressure send‐

um
r
fo
er -G270- .
en
ng
t.
yi Co
op
– Remove bolts -5- from retaining clip -6- and remove pressure
C py
t. rig
gh
accumulator -7-.
ht
pyri by
Vo
o
by c lksw
cted
Installing
agen
Prote AG.
Crafter 2006 ➤

Specified torque
AG. Volkswagen AG d
Securing bolts -5- for retaining 15 Nm lkswagen oes
not
clip Vo
db
y gu
ara
ise nte
Pressure line -1- to gearbox hy‐ th 16 Nm
or eo
draulic pressure sender -G270- ss
au ra
c
ce
e
nl
Disposing of pressure accumulator ⇒ page 18 .
pt
du
an
itte
y li
erm
ab
1.5 Disposing of pressure accumulator
ility
ot p
wit
, is n
– Drain remaining hydraulic fluid from pressure accumulator into
h re
hole
an appropriate container.
spec
es, in part or in w
t to the co
Note
rrectness of i
Observe regulations for disposing of hydraulic fluid.
l purpos
– Clamp pressure accumulator in vice.
nform
ercia
– Using a 2 mm drill bit, drill a hole in the pressure accumulator

about 15 mm -A- from welded seam.
m
at
om
io
The remaining gas charge will escape.
n
c
in t
or
his
e
The pressure accumulator may now be disposed of.

at
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.
1.6 Removing and installing gearbox speed

sender -G38-

Crafter 2006 ➤
Removing
Volkswa
– Remove securing bolt -2- and pull off gearbox
wage speed sender - does n
n AG. gen AG
G38- -3-. Volks ot g
by ua
ed ran
ris tee
tho or
au ac
Note ss
ce
e
nl
pt
The O-ring -4- may remain in the gearbox housing when the gear‐ du
an
itte
y li
box speed sender -G38- -3- is removed.
erm
ab
ility
ot p
wit
Installing
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ It may be necessary to recut the thread in the gearbox housing
for the securing bolt -2-.
l purpos
♦ Fit gearbox speed sender -G38- with new seal and new se‐
curing bolts.
nform
mercia
at
om
Specified torque
ion
c
in t
or
his
ate
do
riv
Securing bolt for gearbox 8 Nm

p
cum
or
speed sender -G38-

f
en
ng
t.
yi Co
Cop py
t. rig
1.7 Removing and installing gear detection sensor -G604-
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Crafter 2006 ➤
Special tools and workshop

equipment required
♦ Engine strut -T50015-
♦ Torque wrench -V.A.G
1783-
♦ Torque wrench -V.A.G
1332-
♦ Engine and gearbox jack -
V.A.G 1383 A-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
Removing ab
ility
ot p
wit
, is n
– Shift gearbox to “N” position. h re

hole
spec
– Unbolt propshaft -A- from gearbox flange and secure prop‐

es, in part or in w
shaft to body using e.g. baling wire.

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
o
by c lksw
cted agen
Prote AG.

Crafter 2006 ➤
– Loosen securing clamp on exhaust pipe -1- and press exhaust

system -2- off front exhaust pipe -arrow-.
Note
lkswage es n
o ot g
♦ Do not move exhaust filter, or the exhaust
ed
by V pipe will leak ⇒ ua
ran
Power unit; Rep. gr. 26 ; Exhausthorsystem .
is tee
ut or
Securing clamp -1- must alwaysss be renewed.
a ac
♦
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
– Position engine and gearbox jack -V.A.G 1383 A- with gearbox
h re
hole
support -V.A.G 1359/2- under gearbox.
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
– Remove bolts -1- and -2- for gearbox carrier.
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
Note
t.
yi Co
Cop py
t. rig
gh
♦ Mark the installation position of the gearbox carrier.
ht
pyri by
Vo
co lksw
by
♦ Depending on construction, there may be four securing bolts
cted agen
Prote AG.
-2- for the gearbox mounting.
– Lower gearbox using engine and gearbox jack -V.A.G 1383 A-

far enough that securing bolts -2- for gear detection sensor -
G604- -1- can be removed.
Crafter 2006 ➤
– Attach engine strut -T50015- to available holes -arrow-.
Note
♦ Depending on construction, other components associated

with optional equipment may be attached to the securing
points -arrows- for the engine support -T50015- .
♦ These additional components must be removed according to
the instructions in the respective workshop manuals.
– Turn spindle on engine strut -T50015- to bring engine to in‐

stallation position.
Caution
It is not permitted to support the engine between the sump and

the steering box.
This manner of support can lead to damage to the steering box.
As a consequence, hydraulic fluid leaks may develop in the
steering box, leading to the failure of power steering.
. Volkswag
To avoid this, use engine strut -T50015- to support
ksw
agen
AG the engine.
en AG
does
n ol ot g
yV ua
edb ran
ris tee
ho
ut or
– Unclip connector -3- from sgear
s a
detection sensor -G604- -1- ac
and remove securing bolts -2-. ce
e
nl
pt
du
Installing an
itte
y li
erm
ab
Install in reverse order of removal, observing the following: ility
ot p
wit
, is n
h re
hole
Note
spec
es, in part or in w
t to the co
The sealing surface of the gear detection sensor -G604- must be

free of oil and grease.
rrectness of i
– Apply sealant ⇒ Electronic parts catalogue “ETKA” to sealing

l purpos
surfaces of gearbox housing and fit gear detection sensor -

G604- .
nf
ercia
– Place gearbox carrier in its previously marked position.

orm
m
– Teach gearbox shift position to gear detection sensor -G604-

atio
m
⇒ Vehicle diagnostic tester.

o
n in
or c
thi
e
Specified torque
t
sd
iva
o
r
rp
cu
♦ Exhaust system; exhaust pipes and silencers ⇒ Rep. gr. 26 ;

o
m
f
en
ng
Exhaust pipes/silencers . yi
t.
Co
op py
♦ Propshaft, Assembly overview, propshaft ⇒ Rep. gr. 39 ; t. C rig
gh ht
yri
Propshaft p by
co Vo
by lksw
cted agen
Prote
AG.
Securing bolts for gear detec‐ 3 Nm

tion sensor -G604-
Securing bolts for propshaft 100 Nm
safety bar
Securing bolt for gearbox carri‐ 58 Nm
er

Crafter 2006 ➤
1.8 Removing and installing electronic man‐

ual gearbox control unit -J514-
Removing
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting battery .
Note
It may be necessary to remove driver seat due to optional equip‐

ment ⇒ Body Repairs; Rep. gr. 72 ; Removing and installing front
seat with fore-and-aft adjustment .
– Pull connector off electronic manual gearbox control unit -

J514- -arrow- -B-.
– Remove securing bolts -A- and remove electronic manual
gearbox control unit -J514- -B-. agen
AG. Volkswagen AG d
oes
ksw not
Installing Vol gu
d by ara
e nte
ris
Install in reverse order of uremoval,
tho observing the following: eo
ra
a c
ss
– Encoding electronic manual gearbox control unit -J514- ⇒ Ve‐
ce
le
un
hicle diagnostic tester.
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
1.9 Table - adapting components
hole
spec
es, in part or in w
Procedure
t to the co
– Release securing screw -1- using e.g. screwdriver and open
dash panel cover on left side. rrectness of i
– Connect ⇒ Vehicle diagnostic tester and select test program.

l purpos
Note
nform
mercia
“Adaptation of clutch for wear” is performed automatically by the

com
tion in
electronic manual gearbox control unit -J514- during travel.

r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
Task Learn clutch release Learn gearbox se‐ Renew and code Relieving pressure,
gh ht
yri by
point lector settings control unit gearbox hydraulics
cop Vo
by lksw
cted agen
Prote AG.
Removing and in‐ X X
stalling clutch; re‐
newing as necessary
stalling slave cylin‐
der with release
bearing; renewing as
necessary
stalling clutch travel
sender -G162- ; re‐
newing as necessary
Crafter 2006 ➤
Task Learn clutch release Learn gearbox se‐ Renew and code Relieving pressure,
point lector settings control unit gearbox hydraulics
Removing and in‐ X
stalling selector lever
-E313- ; renewing as
necessary
stalling gearbox hy‐
draulic pressure
sender -G270- ; re‐
newing as necessary
stalling pressure ac‐
cumulator; renewing
as necessary
wage
Removing and in‐ Xolks es n
ot g
yV
stalling gear detector d b ua
ran
ir se
sensor -G604- ; re‐ tho tee
or
newing as necessary ss
au ac
Removing and in‐ X
ce
e
nl
pt
du
stalling electronic
an
itte
y li
manual gearbox
erm
ab
control unit -J514- ;
ility
ot p
renewing as neces‐
wit
, is n
sary
h re
hole
spec
es, in part or in w
stalling or renewing
t to the co
hydraulic control unit
stalling pan for hy‐
rrectness of i
draulic fluid
l purpos
Checking hydraulic X X
fluid level and toping
up if necessary
nform
ercia
Changing hydraulic X X
m
at
om
fluid
ion
c
in t
r

o
his
e
stalling gearbox hy‐

at
do
riv
draulic pressure
p
cum
or
sender -V387-
f
en
ng
t.
yi Co
Removing and in‐ . Cop
X py X
stalling Shiftmatic
t rig
gh ht
yri by
automatic manual cop Vo
by lksw
gearbox cted agen
Prote AG.
1.10 Removing and installing pan for hydraul‐

ic fluid

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
orise Crafter 2006nte ➤
h eo
Shiftmatic
aut automated gearbox 0B8 - Edition 09.2012 ra
c
ss
ce
le
♦ Engine and gearbox jack -V.A.G 1383 A-
un
pt
an
d
itte
y li
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
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing
of guide -arrow-.
Note

Crafter 2006 ➤

– Remove bolts -1- and -2- and remove gearbox carrier.
Note n AG. Volkswagen AG do

lkswage es n
o ot g
yV
♦ Mark the installation position of the gearbox
ir se
d b carrier. ua
ran
o tee
♦ Depending on construction, theres amay
uth
be four securing bolts or
ac
-2- for the gearbox mounting. s
ce
le
un
pt
an
d
itte
– Drain hydraulic fluid ⇒ page 37 .
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
– Remove suction line -3- and -4- return line from pan.
spec
es, in part or in w
– Remove securing bolts -2- and remove pan -1-.
t to the co
Installing
rrectness of i
l purpos
Note nform
ercia
The sealing surfaces of the pan and the gearbox housing must
m
be free of oil and grease.

com
tion in
r
te o
thi

s
iva
do
surfaces of gearbox housing and fit sump.

r
rp
cum
fo
en
ng
t.
yi
Co
Cop py
pump for gearbox -V387- , “fill” with hydraulic fluid,
t. rig
gh ht
yri
⇒ page 37 Changing hydraulic fluid. p by
co Vo
by lksw
cted agen
Specified torque Prote AG.

Pan to gearbox housing 9.5 Nm
Gearbox mounting to gearbox 30 Nm
carrier M8x20
M10x25
1.11 Removing and installing hydraulic con‐

trol unit

Crafter 2006 ➤
♦ Engine strut -T50015-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
s c
Removing s
ce
le
un
– Carry out the function “Relieving pressure, gearbox hydraul‐ pt

an
d
itte
ics” ⇒ Vehicle diagnostic tester. y li

rm
ab
pe
– Remove securing bolts -2- and pull cover -1- downwards off ility
ot
wit
, is n
guide -arrow-. h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

nform
mercia
Note
a
com
tion in
r
te o

thi
s
iva

do
r
rp
cum
fo

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Crafter 2006 ➤

– Loosen securing clamp on exhaust pipe -1- and press exhaust

system -2- off front exhaust pipe -arrow-.
Note
. Volkswagen AG
gen AG does
♦ Do not move exhaust filter, or the exhaust pipe
Vol will leak ⇒
ksw
a
not
Power unit; Rep. gr. 26 ; Exhaust system
se
d.b
y gu
ara
nte
i
or eo
♦ Securing clamp -1- must always be renewed.
au
th 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
– Remove securing bolts -1- and -2- for gearbox carrier.

in t
or
his
ate
do
priv
cum
or
Note
f
en
ng
t.
yi Co
op py
♦ Mark the installation position of the gearbox carrier. t. C rig
gh ht
pyri by
♦ Depending on construction, there may be four securing bolts
co Vo
by lksw
cted
-2- for the gearbox mounting.
agen
Prote AG.

Crafter 2006 ➤
– Lower gearbox using engine and gearbox jack -V.A.G 1383 A-

far enough that securing bolts -2- for gear detection sensor -
G604- -1- can be removed.
– Attach engine strut -T50015- to available holes -arrow-.
Note
♦ Depending on construction, other components associated

with optional equipment may be attached to the securing
points -arrows- for the engine support -T50015- .

Caution

the steering box.
This manner of support can lead to damage ton Athe
wage
G. Vsteering
olkswagenbox.
AG do
e ks s no
Vol t gu
As a consequence, hydraulic fluid d b leaks may develop in the
y ara
rise of power steering.
steering box, leading to the failure nte
tho eo
au ra
To avoid this, use engine sstrut
s -T50015- to support the engine. c
ce
le
un
pt
an
d
itte
y li
rm
ab
– Unclip connector -3- from gear detection sensor -G604- -1-

pe
ility
and remove securing bolts -2-.

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
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Crafter 2006 ➤
– Remove securing bolt -1- and unclip angled magnet -2-.
Note
♦ Pull a cloth through under the centre shaft and selector sleeve
so that bolt -1- and angled magnet -2- cannot fall into the
gearbox.
♦ Do not let angled magnet -2- touch the metal magnet strip.
– Remove connecting bolt -1- from centre selector shaft.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
– Remove bolt -3- for securing clamp -4-.

un
pt
an
d
itte
y li
– Unbolt pressure line -1- from pressure accumulator -2-.

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 securing bolt from clamp for hydraulic line -3-.

nform
ercia
– Pull return line -2- off connection pipe -1-.

m
a
com
tion in
– Remove union nut from clutch pressure line -8- on hydraulic

r
te o
control unit -4-.

thi
s
iva
do
r
– Remove electrical connections -7- and -5- from solenoid

rp
cum
fo
valves.
en
ng
t.
yi Co
op
– Remove union nut from pressure line -6- on hydraulic control C py
t. rig
unit -4-.
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Crafter 2006 ➤
– Remove bolts -1- and -2-.

– Carefully lever hydraulic control unit -3- off gearbox in vicinity
of selector brake -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
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
Note
es, in part or in w
t to the co
♦ If the pressure line -1- to the pressure accumulator must be
renewed, it must be attached near the selector brake -arrow-
at the same height as the contact surface of the securing bolts.
rrectness of i
♦ Ensure clearance to pressure line -1-.
l purpos
Installing
nform
mercia
at
om
ion
c
in t
or
his
e

at
do
priv
cum
for
en
ng
t.
yi
Note
Co
Cop py
t. rig
gh ht
yri
The sealing surfaces of the hydraulic control unit -4- and the
p by
o Vo
by c lksw
gearbox housing must be free of oil and grease. Prote
cted AG.
agen

surface of gearbox.
– Set hydraulic control unit -4- in place on gearbox housing and
tighten union nuts of pressure line -6- and clutch pressure line
-8- hand tight.
– Push connecting sleeve -2- onto centre selector shaft -1-.
Note
Groove -arrow- must face upwards.
Crafter 2006 ➤
– Push hydraulic control unit -4- further until it rests against

gearbox housing.
Note
Pull a cloth through under the centre shaft and selector sleeve so
that bolt -1- cannot fall into the gearbox.
– Secure centre selector shaft using a new connecting bolt -1-.
AG. Volkswagen AG d
agen oes
o lksw not
V gu
d by ara
– Now tighten bolts -1- and -2- for hydraulic
orise
control unit -3- in the nte
eo
prescribed order -A-, -B-, -C- andaut -D-
h
ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
– Now tighten pressure line -6- and -8-.

te
sd
iva
o
pr
cum
r
fo
en
ng
Note
t.
yi Co
Cop py
t. rig
gh
♦ Pressure line -6- must not contact gearbox housing.
ht
pyri by
Vo
o
by c lksw
♦ Do not yet push return line -2- onto connection -1-.
cted agen
Prote AG.
♦ The return line -2- will be used to add hydraulic fluid ⇒ Elec‐
tronic parts catalogue “ETKA” ⇒ page 35 ..
– Clip connections -7- and -5- onto solenoid valves.

Crafter 2006 ➤
– Tighten union nut for pressure line -1- to pressure accumulator

-2-.
– Attach line clamp -4- and tighten securing bolt -3-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e
– Clip in angled magnet -2-.
horis nte
eo
aut ra
ss c
ce
e
nl
Note
pt
du
an
itte
y li
erm
ab
Do not let angled magnet -2- touch the metal magnet strip.
ility
ot p
wit
, is n
– Now install securing bolt -1-.
h re
hole
spec
es, in part or in w
surfaces of gearbox housing and fit gear detection sensor -
t to the co
G604- .
rrectness of i
Note
l purpos
The sealing surface of the gear detection sensor -G604- must be

free of oil and grease.
nf
ercia
orm
m
– Place gearbox carrier in its previously marked position. atio

om
n in
or c
– Install exhaust system with new securing clamp.

thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Crafter 2006 ➤

Specified torque
Hydraulic control unit pressure 16 Nm
line to pressure accumulator
Hydraulic pump pressure line to 16 Nm
hydraulic control unit
Clutch line to hydraulic control 16 Nm
unit
Securing bolts on bottom of hy‐ 9.5 Nm
. Volkswagen AG
draulic control unit to gearbox kswagen AG does
not
Vol
Securing bolts on top ofehy‐ db
y 7.5 Nm gu
ara
draulic control unit to thgearbox
oris nte
eo
u ra
Securing bolt for connecting
ss a
11.5 Nm c
sleeve to centre selector shaft
ce
le
un
pt
an
d
Securing bolt for angled mag‐ 3 Nm

itte
y li
net to connecting sleeve
rm
ab
pe
ility
Connecting hose retainer to hy‐ 6 Nm
ot
wit
, is n
draulic control unit
h re
hole
spec
es, in part or in w
Exhaust pipes/silencers .
t to the co
♦ Propshaft, Assembly overview, propshaft ⇒ Rep. gr. 39 ;
Propshaft rrectness of i
1.12 Removing and installing gearbox hy‐

l purpos
draulic pressure sender -V387-

nform
ercia

m
a
com
tio

n in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Crafter 2006 ➤
Removing
of guide -arrow-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
– Separate connector -1-. utho
or
s a ac
– Remove securing bolts -arrows-.
s
ce
le
un
pt
– Release wiring harness for gearbox hydraulic pump -V387- .
an
d
itte
y li
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
– Remove union nut from pressure line -1- on gearbox hydraulic
l purpos
pump -V387- -3-.

– Pull suction line -2- off pan.
nform
ercia
– Remove bolts -4- and remove gearbox hydraulic pump -

m
a
com
t
V387- .
ion in
r
te o
Installing thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
AG.
– Screw union nut for pressure line -1- hand-tight onto gearbox
hydraulic pump -V387- -3-.
– Push suction line -2- onto pan.
– Check level of hydraulic fluid and top up ⇒ page 35 .
Specified torque
Bolts for gearbox hydraulic 7.5 Nm
pump -V387- to gearbox hous‐
ing
Union nut for pressure line 16 Nm
1.13 Checking hydraulic fluid level

Crafter 2006 ➤

When pressure has been relieved:
– Remove inspection plug -2- from pan -1-.
Catch any hydraulic fluid which may run out in a commercially
available container.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
ho eo
Note s aut ra
c
s
ce
e
nl
♦ During normal operation, a small quantity of hydraulic fluid

pt
du
an
may collect in tubes -2a- and -3a-, which will then escape when
itte
y li
erm
the inspection plug -2- is removed.

ab
ility
ot p
♦ Filler plug -3- is not needed.

wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove bolt -2- from securing clamp.

l purpos
– Pull return hose -A- off connection pipe -1-.

nform
ercia
Note
m
at
om
ion
c
♦ When return hose -A- is pulled off, the sealing boot may remain
in t
or
in the -hose-.
his
ate
do
riv
♦ Then pull the sealing boot out of the return hose -A- and push
p
cum
for
the boot onto the connection pipe. -1-.

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

Crafter 2006 ➤
– Push a commercially available funnel into the pulled-off return

hose and add hydraulic fluid ⇒ Electronic parts catalogue
“ETKA” -arrow-.
– Add hydraulic fluid ⇒ Electronic parts catalogue “ETKA” until

it begins to run out through hole for fluid inspection plug -2-.
– Screw in inspection plug -2- with new seal.
Note
Specifications for hydraulic fluid ⇒ Maintenance ; Booklet 10.2 .
– Place return hose -A- on connecting pipe -1-.

– Screw in bolt -2- for securing clamp.
AG. Volkswagen A
– Carry out the function “Learn gearbox kswshift position” ⇒ Vehiclees not
agen G do
diagnostic tester. y Vol gu
db ar
e an
ris tee
Specified torque utho or
a ac
ss
ce
e
nl
pt
du
an
Hydraulic fluid inspection plug 35 Nm

itte
y li
erm
ab
Hydraulic fluid filler plug 35 Nm

ility
ot p
wit
, is n
h re
hole
spec
1.14 Draining and filling hydraulic fluid

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
yri by
Draining cop Vo
by lksw
cted agen
Prote
AG.
Crafter 2006 ➤
. Volkswagen AG
does gen AG
– Remove securing bolts -2- andVpull
olks cover -1- downwards out
wa not
of holder -arrow-. ed by gu
ara
ris nte
utho eo
ra
a c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Separate connector -arrow-.
rrectne
Note
ss o
cial p
f in
Separating connector -arrow- will prevent unintentional starting of
form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh
– Remove hydraulic fluid filler plug -2- and hydraulic fluid drain
ht
pyri by
Vo
o
plug -1-.
c by lksw
cted agen
Prote AG.
Catch hydraulic fluid which may run out in a commercially avail‐
able container.
– Screw in hydraulic fluid filler plug -2- and hydraulic fluid drain
plug -1- with new seals -4- and -5-.
Filling
– Remove bolt -2- from securing clamp.

Note
in the hose.

Crafter 2006 ➤
– Push a commercially available funnel into the pulled off return

hose -A- and add the specified quantity of hydraulic fluid -G
004 000- -arrow-.
lkswage es n
o ot g
Note d byV ua
ran
ir se tee
tho
or
♦ Maintain the hydraulic fluid level
au exactly. ac
ss
ce
le
♦ Filling quantity 0.5 litre.
un
pt
an
d
itte
♦ Specifications for hydraulic fluid ⇒ Maintenance ; Booklet
y li
rm
ab
10.2 .
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
– Rejoin separated connector -arrow- for gearbox hydraulic
r
rp
cum
pump -V387- .
fo
en
ng
t.
yi
– Carry out the function “Learn gearbox shift position” ⇒ Vehicle
Co
Cop py
diagnostic tester.
t. rig
gh ht
pyri by
Vo
o
– Separate connector -arrow- again.
c by lksw
cted agen
Prote AG.
– Unscrew inspection plug -3-.
Note
in the hose.
Crafter 2006 ➤
– Unscrew inspection plug -3-.

– Add hydraulic fluid ⇒ Electronic parts catalogue “ETKA” until
it begins to run out through hole for fluid inspection plug -3-.
– Screw in inspection plug -3- with new seal.

– Screw in bolt -2- for securing clamp.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
– Now rejoin separated connector -arrow-
ut
ho
for gearbox hydraulic eo
ra
pump -V387- . ss a c
ce
le
un
– Then clear event memory entries ⇒ Vehicle diagnostic tester.

pt
an
d
itte
y li
Specified torque
erm
ab
ility
ot p

wit
is n
h re
ole,
Hydraulic fluid inspection plug 35 Nm spec

Hydraulic fluid filler plug 35 Nm

t to the co
Oil drain plug 35 Nm

rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Crafter 2006 ➤
2 Removing and installing gearbox

⇒ “2.1 Specified torques for gearbox”, page 41 lkswage es n
o ot g
byV ua
⇒ “2.2 Removing gearbox”, page 41 ir se
d ran
tee
tho
u or
⇒ “2.3 Installing gearbox”, page 45 ss
a ac
ce
e
2.1 Specified torques for gearbox
nl
pt
du
an
itte
y li
erm
Specified torque
ab
ility
ot p
wit
, is n
h re
hole
Bolt for gearbox housing to cyl‐ 38 Nm
spec
inder block
es, in part or in w
t to the co
Bolts for gearbox housing to 38 Nm
starter
Bolt for tachograph sender 10 Nm
rrectness of i
Bolts for gearbox carrier at rear 45 Nm
l purpos
of subframe
Bolts for gearbox support to 45 Nm
nf
ercia
gearbox mounting
orm
m
Bolts for exhaust pipe bracket 23 Nm
atio
om
to gearbox
n in
or c
thi
te
sd
iva
o
r

rp
cu
o
m
Exhaust pipes/silencers .
f
en
ng
t.
yi Co
op
♦ Propshaft, Assembly overview, propshaft ⇒ Rep. gr. 39 ; C py
t. rig
Propshaft
gh ht
pyri by
Vo
co lksw
by
2.2 Removing gearbox
cted agen
Prote AG.

♦ Tensioning strap -T 10038-
♦ Engine support -T50015-
Removing
2. Removing and installing gearbox 41

Crafter 2006 ➤
Note
Cable retainers and clips which were removed or loosened must

be reinstalled in the same positions.
– Disconnect battery in interior ⇒ Electrical system; Rep. gr.

27 ; Battery; Disconnecting battery .
– Raise vehicle.
– Remove noise insulation from gearbox, if fitted.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
– Loosen securing clamp on exhaust pipe -1-.

nl
pt
du
an
itte
y li
– Remove exhaust system in -direction of arrow- ⇒ Rep. gr.
erm
ab
26 ; Exhaust system .
ility
ot p
wit
, is n
h re
hole
Note
spec
es, in part or in w
t to the co
♦ Do not move exhaust filter, or the exhaust pipe will leak ⇒ Rep.
gr. 26 ; Exhaust system .
♦ Securing clamp -1- must always be renewed.
rrectness of i
l purpos
– Remove bracket -1- for exhaust system from gearbox.

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.

Crafter 2006 ➤
– Unscrew bolt -3- for tachograph sender -G75- -2-.

– Always renew seal -1-.
Note
The tachograph sender -G75- is installed only in vehicles with a

tachograph.
– Separate connectors -1- and -2-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
– Unscrew bolts -2- at bottom of gearbox.
an
d
itte
y li
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
ercia

m
a
com
tio
– Strap gearbox to engine and gearbox jack -V.A.G 1383 A- us‐

n in
r
te o
ing tensioning straps -T 10038- .

thi
s
iva
do
– Remove securing bolts for starter.

r
rp
cum
fo
en
ng
t.
yi Co
op py
Note t. C rig
gh ht
pyri by
Vo
co lksw
by
Starter remains attached to engine. Prote
cted AG.
agen

Crafter 2006 ➤
– Unbolt bracket -3- and earth strap -4- from gearbox and tie it
out of way to side.
– Remove gearbox mounting ⇒ page 47 .
– Lower engine and gearbox jack -V.A.G 1383 A- with gearbox
support -V.A.G 1359/2- until the correct working position for
removing gearbox is attained.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
– Attach engine strut -T50015- to available holes as shown in
an
itte
y li
figure -arrow-.
erm
ab
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
♦ Depending on design, other components associated with op‐
t to the co
tional equipment may be attached to the securing points for
the engine strut -T50015- .
rrectness of i
l purpos
nf
ercia
orm
m
atio
m
Caution
o
n in
or c
thi
te
sd
a

iv
o
r
rp
the steering box. cu

o
m
f
en
ng
t.
This manner of support can lead to damage to the steering box.
yi Co
Cop py
t. rig
As a consequence, hydraulic fluid leaks may develop in the
gh ht
yri by
steering box, leading to the failure of power steering.
cop Vo
by lksw
cted agen
Prote AG.
To avoid this, use engine strut -T50015- to support the engine
when removing the gearbox.
– Strap gearbox to engine and gearbox jack -V.A.G 1383 A- with

gearbox support -V.A.G 1359/2- using tensioning strap -T
10038- .

Crafter 2006 ➤
– Remove remaining upper bolts -1-.

– Carefully press gearbox from engine.
– Lower gearbox.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
2.3 Installing gearbox
wit
is n
h re
ole,
Installing
spec
t to the co
– Clean input shaft splines and lightly grease with grease -G 000
100- .
rrectne
The clutch plate must slide easily to and fro on the input shaft.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Crafter 2006 ➤
– Check whether dowel sleeves -A- for aligning engine and

gearbox are fitted in cylinder block and install if necessary
⇒ page 41 .
Note
If dowel sleeves -A- are not fitted, difficulties shifting gears, clutch
problems and possible noises from the gearbox (rattling of gears
which are not engaged) could occur.
AG. Volkswagen AG d
agen oes
lksw not
♦ All cable ties which were opened or cut during gearbox by Vo re‐ gu
ara
moval must be renewed at the same points when rise gearbox is
d
nte
o
installed. auth eo
ra
ss c
♦ If a tachograph is installed, the speed sensor for tachograph
ce
e
nl
pt
must be sealed.
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
A tachograph may be sealed only by an authorised and qualified
spec
workshop.
es, in part or in w
t to the co
– Set gearbox on engine and gearbox jack -V.A.G 1383 A- with
gearbox support -V.A.G 1359/2- and secure using tensioning
rrectness of i
strap -T10038- .
l purpos
– Align gearbox with engine and join.
nform
ercia
Note
m
at
om
io
Do not remove engine and gearbox jack -V.A.G 1383 A- until
n
c
in t
r
gearbox securing bolts are tightened to specified torques.

o
his
ate
do
priv
cum
Further installation of the gearbox is carried out in the reverse
for
en
g
sequence.
n
t.
yi Co
Cop py
– Check oil level in gearbox and top up if necessary
t. rig
gh ht
yri
⇒ page 51 . p by
co Vo
by lksw
cted agen
– Check hydraulic fluid level as appropriate ⇒ page 35 .
Prote AG.
– Teach “gearbox selector positions” to gear detection sender -

G604- ⇒ Vehicle diagnostic tester.
Specified torques
– Carry out road test.

Crafter 2006 ➤
3 Assembly mountings
⇒ “3.1 Removing and installing gearbox mounting”, page 47
3.1 Removing and installing gearbox

mounting
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
Removing
ab
ility
ot p

wit
is n

h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3. Assembly mountings 47
Crafter 2006 ➤
– Remove only bolts -2-.
Note
AG. Volkswagen AG d
agen oes
ksw
Depending on construction, there may be four securing boltsby-2-
Vol not
gu
for the gearbox mounting. rised ara
nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
– Now remove securing bolts -A- for gearbox mounting.
ole,
spec
Installing
t to the co
Specified torque
rrectne
ss
o
cial p
f
carrier M8x20
inform
mer
atio
M10x25
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Crafter 2006 ➤
4 Gearbox housing, clutch housing

⇒ “4.1 Renewing sealing cover in gearbox housing”, page 49
⇒ “4.2 Removing and installing gearbox breather”, page 50
4.1 Renewing sealing coveragein

n Agearbox
G. Volkswagen AG d
oes
housing db
yV
olksw not
gu
ar
e an
ris tee
Special tools and workshop equipment
ut
ho required or
a ac
ss
♦ Fitting sleeve -3241/4-
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
♦ Oil seal extractor lever -VW 681-
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing
– Remove slave cylinder with release bearing ⇒ page 5 .
– Pry out sealing cover -2- using oil seal extractor lever -VW
681- .
Installing
Lightly coat sealing surface of sealing cover with oil.
– Drive in new sealing cover using thrust piece -3241/4- until
cover is flush with gearbox housing.
Continue installation in reverse order of removal:
– Check oil level in gearbox and top up ⇒ page 51 .
– Check hydraulic fluid level ⇒ page 35 .
Specified torques
4. Gearbox housing, clutch housing 49

Crafter 2006 ➤
4.2 Removing and installing gearbox

breather
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
ut ra
Gearbox breather ss a c
ce
le
1- Breather housing with seal

un
pt
an
d
itte
y li
2- Bolts
rm
ab
pe
ility
3- Bleeder hose
ot
wit
, is n
h re
4- Gearbox filler plug
hole
spec
5- Gearbox drain plug
es, in part or in w
t to the co
6- Breather connection
Specified torque
rrectness of i
l purpos
Breather housing bolt 6 Nm

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.

Crafter 2006 ➤
AG. Volkswagen AG d
agen
5 Gearbox oil by
Volksw
oes
not
gu
d ara
e nte
⇒ “5.1 Checking gear oil level”, horipage
s
51 eo
aut ra
⇒ “5.2 Draining and filling sgearbox oil”, page 52
s c
ce
e
nl
pt
du
5.1 Checking gear oil level
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
of guide -arrow-.
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
Note t. Cop py
rig
gh ht
yri by
op Vo
by c lksw
cted
agen
Prote AG.
– Remove securing bolts -arrows- only from pressure accumu‐

lator and lay it to side.
5. Gearbox oil 51
Crafter 2006 ➤
– To check final drive oil, remove oil filler plug -4-.

Correct oil level: 10 mm to lower edge of filler hole -1-.
To measure, use, for example, an Allen key.
– If necessary, top up gear oil.
Gear oil specification ⇒ Maintenance ; Booklet 10.2
– Screw in oil filler plug -1-.
– Attach pressure accumulator. lkswage es n
o ot g
byV ua
Specified torque ir se
d ran
tee
tho
u or
Component ss
a
Specified torque ac
ce
le
Oil filler plug 50 Nm

un
pt
an
d
itte
y li
erm
ab
5.2 Draining and filling gearbox oil
ility
ot p
wit
is n
h re
Draining gear oil
ole,
spec
of guide -arrow-.
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum

r
fo
en
ng
t.
yi Co
Cop py
t. rig
Note
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Remove securing bolts -arrows- from pressure accumulator

and lay it to side.

Crafter 2006 ➤
– Remove oil filler plug -4- and oil drain plug -5-.
Catch gear oil which may run out in a commercially available con‐
tainer.
– After the gear oil has drained, screw oil drain plug in again
-5-.
Filling with gear oil
– Fill with gear oil.
Gear oil specification ⇒ Maintenance ; Booklet 10.2
Gearbox capacity 1.5 l.
The oil level is correct when the gearboxwisgefilled
n AG. to 10 mm below
Volkswagen AG
does
s a
the lower edge of filler hole -4-. yV
olk not
gu b ara
ed nte
oris e
th or
au
Note ss
ac
ce
e
nl
pt
du
To measure, use, for example, an Allen key.
an
itte
y li
erm
ab
ility
– Screw in oil filler plug -4-.
ot p
wit
, is n
Specified torque
h re
hole
spec
es, in part or in w
t to the co
Oil filler plug 50 Nm
Oil drain plug 60 Nm
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
5. Gearbox oil 53
AG. Volkswagen AG d
agen oes
olksw not
yV gu
Crafter 2006 ➤ ed b ara
nte
ris
Shiftmatic automated gearbox 0B8 - Edition 09.2012utho eo
ra
s a c
s
ce
le
un
35 – Gears, shafts
pt
an
d
itte
y li
rm
ab
pe
ility
1 Input shaft
ot
wit
, is n
h re
hole
⇒ “1.1 Renewing input shaft seal”, page 54
spec
es, in part or in w
t to the co
1.1 Renewing input shaft seal
rrectness of i
♦ Puller -T10055-
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
♦ Puller -T50012-
Prote AG.

– Remove slave cylinder with release bearing ⇒ page 5 .
Removing
To pull out input shaft seal -1-, proceed as follows:
54 Rep. gr.35 - Gears, shafts

Crafter 2006 ➤
– To pull out seal, screw sheet metal screw of about 4 mm di‐

ameter into seal -arrow-.
♦ Screw sheet metal screw in so that it jams between seal and
metal ring.
Note
Do not screw in sheet metal screw too far to avoid damaging

bearing behind it.
– Pull out seal -1- using puller -T10055- .

Installing

Coat sealing lips of new seal with oil.
– Drive in new oil seal using thrust piece -T50012- until seal is
flush with gearbox housing.
– Check oil level in gearbox and top up ⇒ page 51 .
– Check hydraulic fluid level ⇒ page 35 .
Specified torques
Securing bolts for slave cylin‐ 9 Nm wagen AG. Volkswagen AG doe
der with clutch release bearing lks
yV
o sn ot g
ua
edb ran
ris tee
ho
aut or
ac
ss
ce
le
un
pt
an
d
itte
y li
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
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Input shaft 55
Crafter 2006 ➤
2 Output shaft
⇒ “2.1 Renewing output shaft seal”, page 56
2.1 Renewing output shaft seal

♦ Counterhold tool -3435-
♦ Thrust piece -T10089-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
♦ Separating tool Kukko 17/2 not illustrated

pt
du
an
itte
y li
♦ Counter support Kukko 22/2 not illustrated

erm
ab
ility
ot p
Removing
wit
, is n
h re

hole
spec
shaft to body using e.g. “baling wire”.

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
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
56 Rep. gr.35 - Gears, shafts

Crafter 2006 ➤
– Unscrew securing nut -A- from propshaft flange.
– Set up pulling device as shown in figure and pull off propshaft.

A - Separating tool Kukko 17/2
B - Counter support Kukko 22/2
. Volkswagen AG
– Remove pulling device.
ksw
agen
AG does
not
ol
yV g
– Using, e.g., ea
d bscrewdriver, pry out seal for outputuashaft.
ran
ris tee
ho
aut or
ac
ss ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
Installing
h re
ole,
spec
Coat sealing lips of seal with oil.

t to the co
– Drive in new oil seal using thrust piece -T10089- until seal is
flush with housing.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e
– Install propshaft flange and screw in securing nut -A-.

t
sd
iva
o
pr
Continue installation in reverse order of removal.

um
r
fo
en
ng
t.
yi
Check gear oil level ⇒ page 51 .
Co
Cop py
t. rig
gh
Specified torque
ht
pyri by
Vo
o
by c lksw
cted agen
Component
Prote Specified torque
AG.
Securing nut for propshaft 160 Nm

Propshaft to gearbox flange 15 Nm + 1/4 turn (90°) further
2. Output shaft 57

Service: Crafter 2006

Uploaded by

Copyright:

Available Formats

Service: Crafter 2006

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Service: Crafter 2006

Uploaded by

Copyright:

Available Formats

Service

All rights reserved.

Copyright © 2015 Volkswagen AG, Wolfsburg K0059030320

2.1 Assembly overview - clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.2 Removing and installing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.2 Removing and installing selector lever E313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.4 Removing and installing pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.5 Disposing of pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a 18

1.7 Removing and installing gear detection sensor G604 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1.9 Table - adapting components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1.14 Draining and filling hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

5.2 Draining and filling gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

1.1 Gearbox identification

Only the part number appears on the gearbox.

2.1 General repair instructions for gearbox‐

♦ Apply sealing paste uniformly but not too thick.

♦ Radial oil seals.

Before installing radial oil seals:

♦ Check oil level and top up if necessary ⇒ page 51 .

♦ Retaining rings must locate properly in grooves.

♦ Do not cant especially delicate parts, such as clutch pressure

plates. Loosen and tighten bolts and nuts in stages in a diag‐

♦ Specified torques settings are specified for unoiled bolts and

2.8 Gear wheels

3 Technical data AG. Volkswagen AG d

1st gear 3925x4514 i1 = 5.014

Hydraulic unit 0.5 l

4 Rep. gr.00 - Technical data

♦ Torque wrench -V.A.G 1331-

– Remove Shiftmatic automated manual gearbox ⇒ page 41 .

– Separate connector for clutch travel sender -G162- -1-.

To prevent hydraulic fluid from escaping, seal the pulled-off hy‐

♦ Do not apply compressed air to removed slave cylinder with

In spite of a bleeder valve on the slave cylinder with release bear‐

ing, no bleeding should be carried out because the entire hy‐

Component Specified torque

Securing bolts for slave cylin‐ 9 Nm

– Carry out the function “Learn clutch release point” ⇒ Vehicle o

1.2 Removing and installing clutch travel

6 Rep. gr.30 - Clutch

– Release wiring for clutch travel sender -G162- -1-.

Install in reverse order of removal, observing the following:

♦ ⇒ “2.1 Specified torques for gearbox”, page 41

Component Specified torque

Securing bolts for clutch travel 3 Nm

❑ Removing and installing

Installation position of clutch plate:

lettering “Getriebsseite” must face

❑ Check ends of dia‐

2.2 Removing and installing clutch

8 Rep. gr.30 - Clutch

♦ Torque wrench -V.A.G 1331-

♦ Centring mandrel -3434-

If vehicle is manoeuvred for a longer time with a slipping clutch,

the temperature of the clutch will rise. There is a two-stage clutch-

protection function to warn of critical temperatures. Above a cal‐

culated clutch temperature of 250 °C, the clutch will be closed

♦ Pressure plate contact surface and clutch plate lining must

♦ Tighten securing bolts diagonally and evenly to prevent dam‐