6 Speed Dual Clutch Gearbox 0DD Hybrid Eng

Service
Workshop Manual
Golf 2013 ➤
Golf 2017 ➤
Passat 2015 ➤
Passat Variant 2015 ➤
6-speed dual clutch gearbox 0DD, hybrid vehicles
Edition 09.2018
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - differential
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.
Golf 2013 ➤ , Golf 2017 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤
6-speed dual clutch gearbox 0DD, hybrid vehicles - Edition 09.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when working on vehicles with high-voltage system . . . . . . . . . . . . . . 1
1.2 General safety provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 6
1.4 Safety precautions when using testers and measuring instruments during a road test . . . . 6
1.5 Safety precautions when tow-starting or towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4 Safety functions of gearbox control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.1 Allocation gearbox - engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.1 Assembly overview - dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2 Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1 Mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.1 Assembly overview - mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.3 Removing and installing mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.1 Assembly overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.2 Emergency release from position P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.3 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.4 Moving push-button in the handle to installation position . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.5 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.6 Removing and installing gear selector cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.7 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.8 Checking and adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.9 Renewing selector shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.3 Specified torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6 Gear oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.1 Assembly overview - gear oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.2 Removing and installing gear oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.3 Removing and installing gear oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
7.1 Overview of fitting locations - oil drain and inspection plugs . . . . . . . . . . . . . . . . . . . . . . . . 61
Contents i
7.2 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

7.3 Draining and filling gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
7.4 Filling with gear oil after mechatronic unit has been renewed . . . . . . . . . . . . . . . . . . . . . . 71
8 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
8.1 System overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
8.2 Assembly overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
8.3 Assembly overview - hybrid module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
8.4 Removing hybrid module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
8.5 Renewing hybrid module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.6 Installing hybrid module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
8.7 Removing and installing rotor position sensor and temperature sender . . . . . . . . . . . . . . 89
8.8 Renewing sealing cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1 Dismantling and assembling gears and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

1 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.1 Overview of fitting locations - seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.2 Renewing left seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
ii Contents
00 – Technical data
1 Safety information
(VRL012225; Edition 09.2018)
⇒ “1.1 Safety precautions when working on vehicles with high-
voltage system”, page 1
⇒ “1.2 General safety provisions”, page 5
⇒ “1.3 Safety measures when working on vehicles with a start/
stop system”, page 6
⇒ “1.4 Safety precautions when using testers and measuring in‐
struments during a road test”, page 6
⇒ “1.5 Safety precautions when tow-starting or towing”,
page 7
1.1 Safety precautions when working on ve‐

hicles with high-voltage system
⇒ “1.1.1 General safety precautions when working on a high-volt‐
age system”, page 1
⇒ “1.1.2 Safety precautions for work on a high-voltage system for
which the high-voltage system must be de-energised”,
page 2
⇒ “1.1.3 Safety precautions when re-energising high-voltage sys‐
tem”, page 3
⇒ “1.1.4 Safety precautions when working in the vicinity of high-
voltage components”, page 3
which the ignition must be switched on”, page 5
which the ignition must not be switched on”, page 5
1.1.1 General safety precautions when work‐

ing on a high-voltage system
Note
In the event of uncertainties regarding the terms “high-voltage

technician”, “high-voltage expert” or the high voltage system, the
relevant importer must be contacted prior to the start of all work.
1. Safety information 1
DANGER!
Danger to life due to high voltage

♦ The high-voltage system is under high voltage. Severe or
fatal injury due to electric shock.
♦ Persons with life-preserving or other electronic medical
devices in or on their body must not perform any work on
the high-voltage system. Such medical devices include
internal analgesic pumps, implanted defibrillators, pace‐
makers, insulin pumps and hearing aids.
♦ The high-voltage system must be de-energised by a suit‐
ably qualified technician.
DANGER!
Risk of injury due to unexpected motor start

♦ On electric and hybrid vehicles, it can easily be missed
that the vehicle is in „ready“ mode. There is a risk of parts
of the body becoming trapped or drawn in.
♦ Switch off ignition.
♦ Always store the ignition key outside the vehicle.
DANGER!
Handling high-voltage cables

• Never support yourself on high-voltage cables or high-
voltage connectors --> risk of damage to the insulation.
• Never support your tools on high-voltage cables or high-
voltage connectors --> risk of damage to the insulation.
• Never kink or severely bend high-voltage cables --> risk
of damage to the insulation.
• Always connect high-voltage connectors according to
coding.
1.1.2 Safety precautions for work on a high-

voltage system for which the high-volt‐
age system must be de-energised
Always de-energise the high-voltage system using the “Guided
fault finding” function ⇒ Rep. gr. 93 ; De-energising high-voltage
system .
The types of work for which the high-voltage system has to be de-
energised are indicated in ⇒ Rep. gr. 00 ; Safety instructions;
Safety precautions when working on vehicles with high-voltage
system .
2 Rep. gr.00 - Technical data

DANGER!
Hazardous voltage
Severe or fatal injury due to electric shock.
♦ The high-voltage system must be de-energised only by a
suitably qualified technician (high-voltage technician).
♦ After the high-voltage system has been de-energised,
there must be no doubts about the successful completion
of the process. Only the vehicle diagnostic tester and the
“Guided fault finding” function must be used to verify
whether the high-voltage system has been de-energised
correctly.
♦ The qualified technician (high-voltage technician) ascer‐
tains that the system is de-energised, and secures it to
prevent reactivation using padlock - T40262/1- . In addi‐
tion to locking the high-voltage system, the ignition key
and the key for the padlock - T40262/1- must be stored at
a safe location by the qualified technician.
♦ The qualified technician (high-voltage technician) identi‐
fies the vehicle by attaching the appropriate warning
signs.
1.1.3 Safety precautions when re-energising

high-voltage system
Always re-energise the high-voltage system using the “Guided
fault finding” function ⇒ Rep. gr. 93 ; Re-energising high-voltage
system .
DANGER!
Hazardous voltage
Risk of severe or fatal injury due to electric shock.
♦ The high-voltage system must be re-energised only by a
suitably qualified technician (high-voltage technician).
♦ Only the vehicle diagnostic tester and the “Guided fault
finding” function must be used to verify whether the high-
voltage system has been re-energised correctly.
♦ The qualified technician (high-voltage technician) must re-
energise the vehicle.
♦ The qualified technician (high-voltage technician) identi‐
fies the vehicle by attaching the appropriate warning
signs.
1.1.4 Safety precautions when working in the

vicinity of high-voltage components
The types of work for which the high-voltage system has to be de-
energised are indicated in ⇒ Rep. gr. 00 ; Safety instructions;
Safety precautions when working on vehicles with high-voltage
system .
DANGER!
Hazardous voltage in the event of damaged high-voltage com‐

ponents
♦ The high-voltage system is under high voltage. Damage
to high-voltage components will result in severe or fatal
injury due to electric shock.
♦ Metal-removing, deforming and sharp-edged tools are
prohibited.
♦ Heat sources such as welding, soldering, hot air and ther‐
mal bonding are prohibited.
♦ Before starting work, carry out a visual check on the high-
voltage components in the area of work.
♦ When working in the engine compartment, carry out a vis‐
ual check on the maintenance connector for high-voltage
system, power and control electronics for electric drive,
the electric drive motor, the air conditioner compressor,
control unit for high-voltage battery charging unit and the
high-voltage cables.
♦ When working on the underbody, carry out a visual check
on the high-voltage heater (PTC), high-voltage cables,
hybrid battery unit and covers.
♦ Carry out a visual check on all potential equalisation lines.
When carrying out the visual check, observe the following:
♦ The high-voltage components must not reveal any exter‐
nal damage.
♦ The insulation of the high-voltage cables and the potential
equalisation lines must not be damaged.
♦ The high-voltage cables must not show any unusual de‐
formations.
♦ Each high-voltage component must be clearly identified
with a red warning sticker.


voltage system for which the ignition
must be switched on
DANGER!
Risk of injury due to unexpected motor/engine start and risk of

poisoning in unventilated rooms when working with the ignition
switched or when the vehicles is activated for driving. There is
a risk of parts of the body becoming trapped or drawn in.
Proceed as follows before switching on the ignition:
♦ Shift selector lever to position P.
♦ Activate the parking brake.
♦ Open the bonnet.
♦ Connect the 12 V charging unit to the jump start contacts
of the 12 V onboard supply.
♦ Switch on ignition.

voltage system for which the ignition
must not be switched on
DANGER!
Risk of injury due to unexpected motor start

♦ On electric and hybrid vehicles, it can easily be missed
that the vehicle is in „ready“ mode. There is a risk of parts
of the body becoming trapped or drawn in.
♦ Always store the ignition key outside the vehicle.
1.2 General safety provisions

To prevent personal injury and material damage to the vehicle,
observe the following:
WARNING
Risk of injury and accident by accidental engagement of gear

while engine is running.
♦ Before work is done with the engine running, shift the se‐
lector lever to the “P” position, and pull the parking brake
button to activate the electromechanical parking brake.
To prevent personal injury and damage to or destruction of elec‐

trical and electronic components, observe the following:
♦ Connect and disconnect measuring and testing devices only
with the ignition switched off.
Caution
Risk of irreparable damage to electronic components when

disconnecting battery.
♦ Observe the necessary measures when disconnecting the
battery.
♦ Disconnect battery only after the ignition has been switch‐
ed off.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

Disconnecting and reconnecting battery .
1.3 Safety measures when working on ve‐

hicles with a start/stop system
During work on vehicles with start/stop system, observe the fol‐
lowing:
WARNING
Injury hazard as a result of automatic engine start in vehicles

with start/stop system.
♦ In vehicles with the start/stop system activated (identifia‐
ble by an indication in the dash panel insert), the engine
can start automatically if the required conditions are met.
♦ When working on the vehicle, therefore, ensure that the
start/stop system is deactivated (switch ignition off, then
switch ignition back on when required).
1.4 Safety precautions when using testers

and measuring instruments during a
road test
Observe the following if test and measuring instruments are re‐
quired during a road test:
WARNING
Risk of accident due to distraction and inadequate securing of

test and measuring equipment.
Danger as a result of activation of front passenger airbag in
event of an accident.
• Operation of test and measuring equipment while driving
results in distraction.
• Greater injury hazard as a result of unsecured test and
measuring equipment.
♦ Always strap in place test and measuring equipment on
rear seat and have a 2nd person sitting on the rear seat
to operate them.

1.5 Safety precautions when tow-starting or

towing
Caution
If the vehicle has to be towed, the selector lever must be in the

“N” position and the vehicle must be towed at a speed no
greater than 50 km/h and for a distance not exceeding 50 km.
Otherwise the gearbox will be damaged.
Note
It is not possible to tow-start the engine, e.g. if the battery is too

flat or the starter is not functioning.
2 Identification
2.1 Gearbox identification
1 - Gearbox code
2 - Day of production
3 - Month of production
4 - Year of production
5 - Serial number
6 - Minute of production
7 - Hour of production
8 - Factory
Volkswagen Technical Site: http://vwts.ru http://vwts.info
Note
The gearbox code is also indicated on the vehicle data stickers.

3 Repair instructions
⇒ “3.1 General information”, page 9
⇒ “3.2 Rules for cleanliness”, page 10
⇒ “3.3 General repair instructions”, page 10
⇒ “3.4 Safety functions of gearbox control unit”, page 11
3.1 General information

Gearbox
The dual clutch gearbox 0DD is structured like a 6-speed manual
gearbox. The engine torque is transferred to the gearbox via the
dual-mass flywheel. The gearbox works like an automatic gear‐
box because of the two multiplate clutches which are activated
alternately by hydraulic means: the gears are shifted automati‐
cally or manually with the selector lever in Tiptronic position.
Selector mechanism
Only for selector lever position “P” the parking lock is engaged
mechanically via the selector lever cable. All other selector lever
positions and shift operations are transmitted from the selector
lever - J743- (selector mechanism) via the CAN bus to the me‐
chatronic unit for dual clutch gearbox - E313- .
Gear oil
The dual clutch gearbox 0DD only has one oil system.
The oil system lubricates the gears, shafts, final drives, clutches
and mechatronic unit for dual clutch gearbox - J743- .
Caution
Risk of damage to gearbox.

♦ Use only the gear oil available as a replacement part for
the 6-speed dual clutch gearbox 0DD ⇒ Electronic parts
catalogue .
♦ Other oils will lead to malfunctions or failure of the gear‐
box.
Gear oil filter change - »Yes or no?«
Note
The gear oil filter does not have to be changed as a matter of

course.
Do not change the filter if:

♦ The gear oil cooler or its O-rings have been renewed and no
coolant has got into the oil.
♦ Seals and O-rings of the gearbox have been renewed.
♦ The sump or mechatronic unit were renewed.
♦ The service interval was reached.
Filter must be changed if:
♦ Metal particles have been found in the oil.
♦ The clutch is burnt or has a mechanical defect.
3. Repair instructions 9
Gear change point variations for gradients

An additional gear change map automatically selects gear
changes for gradients dependent upon accelerator pedal position
and driving speed.
• Gear change map for extreme uphill stretches is matched to
engine output
• Gear change map for extreme downhill stretches is matched
to the braking effect of the engine
• If a gear is selected directly via the Tiptronic system, it is also
possible to use the braking effect of the engine in a specific
gear, e.g. when driving down a slope with a trailer attached.
3.2 Rules for cleanliness

♦ Carefully clean connection points and the surrounding area
with engine cleaner or brake cleaner and dry thoroughly before
opening.
♦ Clean the gearbox and gearbox components using cleaning
solution - D 009 401 04- .
♦ Use lint-free cloths for cleaning.
♦ Seal open lines and connections immediately using clean
plugs or sealing caps from engine bung set - VAS 6122- .
♦ Place removed parts on a clean surface and cover them over.
Use sheeting and paper for this purpose. Use lint-free cloths.
♦ If repair work cannot be performed immediately, cover new
parts which have been removed from their packing.
♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing.
♦ Protect disconnected electrical connections from dirt and wa‐
ter and only reconnect in dry condition.
3.3 General repair instructions

♦ To ensure flawless and successful gearbox repairs, the great‐
est care and cleanliness as well as the use of good and proper
tools are essential. Also note the basic rules on safety when
performing repair procedures.
♦ A number of generally applicable instructions for the various
repair procedures - which were previously repeated at numer‐
ous places in the Workshop Manual - are summarised here.
They apply for this particular workshop manual.
Guided Fault Finding, vehicle self-diagnosis and test instruments
♦ Before performing repairs on the gearbox, determine the
cause of the fault as accurately as possible using modes of
operation Guided Fault Finding , Vehicle Self-Diagno-
sis and Test Instruments ⇒ Vehicle diagnostic tester.
Special tool
For a complete list of special tools used in this workshop manual,
see ⇒ "Workshop equipment and special tools" .
Regulations concerning oil handling, environment and disposal
♦ Be careful when handling gear oil and other oil.
♦ Dispose of drained oil according to regulations.
♦ Observe the legal environmental and disposal regulations.
♦ Always follow the instructions on the oil packaging.

Gearbox
♦ Do not run engine or tow vehicle with sump removed or when
there is no gear oil in the gearbox.
♦ Thoroughly clean all unions and adjacent areas before dis‐
connecting.
♦ When installing, ensure that the dowel sleeves are fitted cor‐
rectly.
O-rings, seals, gaskets
♦ Always renew O-rings, seals and gaskets.
♦ After removing gaskets and seals, always inspect contact sur‐
face of housing or shaft for burrs resulting from removal or for
other signs of damage.
♦ Thoroughly clean housing joint surfaces before assembling.
♦ Always renew paper gaskets. Remove previous gaskets com‐
pletely, and thoroughly clean all sealing surfaces.
♦ Lightly lubricate outer circumference and sealing lip of oil seals
with gearbox oil before installing.
♦ Moisten O-rings with gear oil or Vaseline to prevent crushing
of the rings during assembly.
♦ Never use any other types of lubrication in the gear oil area.
Otherwise there is a risk of malfunctions in the hydraulic gear‐
box control.
♦ The open side of the oil seals faces toward the side with fluid
filling.
♦ Press in new oil seals so that sealing lip does not contact the
shaft in the same place as the old seal (make use of insertion
depth tolerances).
♦ Observe rules for cleanliness ⇒ page 10 .
Locking devices
♦ Do not overstretch retaining rings.
♦ Always renew retaining rings which have been damaged or
overstretched.
♦ Retaining rings must locate properly in grooves.
Nuts and bolts
♦ Loosen bolts in sequence opposite to the tightening sequence.
♦ Nuts and bolts which secure covers and housings should be
loosened and tightened diagonally in stages if no tightening
sequence is specified.
♦ Renew self-locking nut.
♦ Clean threads of bolts which are to be installed with locking
fluid using a wire brush. Then insert bolts with locking fluid -
AMV 185 101 A1- .
♦ Specified torques given are for unoiled nuts, bolts and screws.
3.4 Safety functions of gearbox control unit

If one or several components or sensors fail, the gearbox control
unit will activate corresponding alternative functions. This will en‐
sure continued operation of the gearbox despite the impaired
functionality and quality of gear change operations caused by the
respective failure and the gearbox will be prevented from being
destroyed.
3. Repair instructions 11
The failures detected by the gearbox may cause 4 different states.

♦ 1.: The fault is stored, and a substitute program allows for
continuing the journey (with some restrictions). The driver is
not informed of this state, because it is not critical for the safety
or the gearbox. The selector lever position display in the dash
panel insert shows the current selector lever position as usual.
The driver may, if at all, notice the state due to the driving
characteristics and thus automatically contact an authorised
workshop.
♦ 2.: Particular selector lever positions are flashing in the selec‐
tor lever position display in the dash panel insert. The driver is
being warned that it is not possible to select this gear at the
moment. This happens if, for example, the position “D” is se‐
lected while the vehicle is still reversing (selector lever in
position “R” and vehicle moves rearwards). In this case, the
selector lever position “D” is flashing in the selector lever po‐
sition display in the dash panel insert. In this situation, the
gearbox control unit prevents the 1st gear from being engaged
to prevent damage to the gearbox. As soon as the vehicle has
stopped, the 1st gear is engaged.
♦ 3.: The selector lever position display in the dash panel insert
is completely illuminated and flashes. The selected selector
lever position is recognisable in the dash panel insert, e.g. “D”
is highlighted. This indicates a gearbox overload or that the
max. gearbox temperature has been exceeded (overtemper‐
ature), e.g. when towing a trailer which is too heavy.
♦ 4.: In the event of a critical fault, the selector lever position
display in the dash panel insert is completely illuminated and
flashes. The current selector lever position is no longer indi‐
cated in the dash panel insert. This state is critical for the safety
or the gearbox. It may no longer be possible to select all gears.
The flashing selector lever position display requests the driver
to contact an authorised workshop.

4 Technical data
4.1 Allocation gearbox - engine
4.1.1 Golf 2013 ►, Golf 2017 ►

Dual clutch gearbox 0DD
Identification code PZZ; QMT, QXW,
QMU, RJW, RNT,
RNU, RYU, SBZ,
TEA
Engine 1.4 l - 110 kW TSI
4.1.2 Passat 2015 ►, Passat Estate 2015 ►

Dual clutch gearbox 0DD
Identification code QBM, RJX, RNN,
RNV, RXG, RYW,
SCB, TEC
Engine 1.4 l - 115 kW TSI
4.2 Capacities
Capacities Dual clutch gearbox 0DD
Initial filling 8.1 l
Changing approx. 7 l
Change interval ⇒ Maintenance tables
Lubricant Gear oil ⇒ Electronic parts catalogue
(ETKA)
Caution

the 6-speed dual clutch gearbox 0DD ⇒ Electronic parts
catalogue .
box.
– Check gear oil level ⇒ page 61 .

– Top up gear oil upon repair work ⇒ page 61 .
4. Technical data 13
30 – Clutch
1 Clutch
⇒ “1.1 Assembly overview - dual clutch”, page 14
⇒ “1.2 Renewing input shaft seal”, page 14
1.1 Assembly overview - dual clutch

The dual clutch is part of the hybrid module and cannot be re‐
newed individually. See
⇒ “8.2 Assembly overview - gearbox”, page 75 .
1.2 Renewing input shaft seal

Special tools and workshop equipment required
♦ Extractor hooks -T20143/1-
♦ Thrust piece - T40403- with sleeve
Sequence of operations
• Gearbox is removed ⇒ page 53 .
– Lever out input shaft oil seal using extractor hook -T20143/1- .
– Apply gear oil to circumference and sealing lips of new oil seal.
• Installation position: open side of seal faces towards gearbox
– Fit sleeve of thrust piece - T40403- onto input shaft.
– Carefully push seal onto sleeve.
– Using thrust piece - T40403- , drive in seal for input shaft to
stop.
14 Rep. gr.30 - Clutch

34 – Controls, housing
1 Mechatronic unit
⇒ “1.1 Assembly overview - mechatronic unit”, page 15
⇒ “1.2 Removing and installing sump”, page 16
⇒ “1.3 Removing and installing mechatronic unit”, page 19
1.1 Assembly overview - mechatronic unit
1 - Bolt
❑ Qty. 7
❑ Renew after removal
❑ Specified torque and
tightening sequence
⇒ page 16
2 - Sump
❑ Removing and installing
⇒ page 16
3 - Seal
4 - Seal
5 - Bolt
❑ Qty. 15
❑ Specified torque and
tightening sequence
⇒ page 16
6 - Mechatronic unit for dual
clutch gearbox - J743-
❑ With O-rings on connec‐
tor
❑ Renew O-rings after
each removal.
⇒ page 19
7 - Seal
8 - Seal
9 - O-ring
1. Mechatronic unit 15
Sump - specified torque and tightening sequence
Note
Renew bolts that are tightened with turning further angle.
– Tighten bolts diagonally in several stages:

Stage Bolts Specified torque/turning further angle:
1. -Arrows- Screw in to contact by hand.
2. -Arrows- 8 Nm + 90° further
Mechatronic unit for dual clutch gearbox - J743- - specified torque

and tightening sequence
Note
Renew bolts that are tightened with turning further angle.
– Tighten bolts in stages in sequence shown:

Stage Bolts Specified torque/turning further angle:
1. -1 … 15- Screw in to contact by hand.
2. -1 … 15- 5 Nm + 270° further
1.2 Removing and installing sump

♦ Used oil collector and extractor - VAS 6622A-
16 Rep. gr.34 - Controls, housing

Removing
Caution
Risk of gearbox damage.

♦ Do not run the engine or tow the vehicle with sump re‐
moved or when there is no gear oil in the gearbox.
Note

♦ Refer to general repair instructions ⇒ page 10 .
DANGER!

♦ Have a “high-voltage technician (HVT)” de-energise the
high-voltage system.
♦ Work on a de-energised high voltage system must only be
performed by an “electrically instructed person (EIP)”.
– De-energise high-voltage system ⇒ Rep. gr. 93 ; De-ener‐

gising the high-voltage system .
– Remove bracket for high voltage battery charger ⇒ Rep. gr.
93 ; Charging unit for high-voltage battery; Removing and in‐
stalling charging unit 1 for high-voltage battery - AX4- .
– Disconnect connectors -1, 2-, and move wires clear to one
side.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Removing and installing noise
insulation .
– Disconnect connector -1- on engine temperature sender 2 -

G652- , and move engine wiring harness on sump clear to one
side.
Note
Disregard -item 2-.
– Disconnect connector -1-.

– Unscrew bolt -3-, and push coolant circulation pump before
power and control electronics for electric drive - V508- towards
right side.
Note
Disregard -item 2-.
– Place used oil collection and extraction unit - VAS 6622A- be‐
low gearbox.
– Unscrew bolts -arrows- in a diagonal sequence.
– Remove sump -1- with sump gasket. Drain any remaining gear
oil in sump into used oil collection and extraction unit - VAS
6622A- .
Installing
Install in reverse order of removal, observing the following:
Note
Renew any seals, gaskets and bolts after each removal.
– Remove any oil and grease from sealing surfaces.

– Fit sump with sump gasket, and tighten bolts ⇒ page 16 .
– Install coolant circulation pump before power and control elec‐

tronics for electric drive - V508-
– Fill gear oil via oil filler plug for mechatronic unit area
⇒ page 71
– Install bracket for high voltage battery charger ⇒ Rep. gr. 93 ;
Charging unit for high-voltage battery; Removing and installing
charging unit 1 for high-voltage battery - AX4- .
DANGER!

♦ Have a “high-voltage technician (HVT)” re-energise the
– Re-energise high-voltage system ⇒ Rep. gr. 93 ; Re-ener‐

gising high-voltage system .
Torque settings
♦ ⇒ Fig. ““Sump - specified torque and tightening sequence”“ ,
page 16
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Assembly overview - noise insulation

1.3 Removing and installing mechatronic

unit
♦ Protective mat
Removing
Caution

♦ Do not run the engine or tow the vehicle with sump re‐
moved or when there is no gear oil in the gearbox.
Note

♦ Refer to general repair instructions ⇒ page 10 .
DANGER!

– Remove sump ⇒ page 16 .

– Detach electrical connection -1- from coolant changeover
valve 1 - N632- .
– Unscrew bolts -arrows-.
Note
-Items 2, 3- can be disregarded.
– Remove lower left coolant hose from radiator. ⇒ 4-cyl. injec‐

tion engine (hybrid); Rep. gr. 19 ; Cooling system, coolant
– Remove radiator cowl with radiator fan -arrow- ⇒ Rep. gr. 19 ;

Radiator, radiator fan; Removing and installing radiator cowl .
– Place protective mat between radiator and engine.
– Loosen and unscrew bolts in the sequence -15 to 1-.
Caution
Risk of damage to the mechatronic unit for dual clutch gearbox

- J743- caused by electrostatic discharge.
♦ Do NOT touch connector contacts in electrical connector
for mechatronic unit for dual clutch gearbox - J743- with
bare hands.
– Touch an earth connection, a radiator in the workshop or a

lifting platform with the hand (without gloves) in order to dis‐
charge yourself.
– Carefully pull mechatronic unit off gearbox, and remove it
downwards.

Laying mechatronic unit to side properly:

– Put down mechatronic unit so that sensors -arrows- are point‐
ing upwards.
Installing
Note
♦ Renew bolts that are tightened with turning further angle.

♦ Renew seals after each removal.
♦ The help of a second mechanic is necessary to install the me‐
chatronic unit.
– Screw a stud -2- on left and right into gearbox, e.g. guide pin
- T40199- .
– Before touching the mechatronic unit, touch an earth connec‐
tion, a radiator in the workshop or a lifting platform with the
hand (without gloves) in order to discharge yourself.
The coolant hoses in front of the gearbox make the installation of
the mechatronic unit difficult.
– While one mechanic holds the coolant hoses to the side to
create access to the gearbox, the second mechanic must fit
the mechatronic unit in the gearbox.
– To install the mechatronic unit -1-, carefully set it on the threa‐
ded studs -2- in the gearbox while ensuring that the seal -3- is
properly seated on the left and right.
– Tighten bolts of mechatronic unit for dual clutch gearbox -
J743- ⇒ page 16 .
– Install lower left coolant hose to radiator and add coolant ⇒

Rep. gr. 19 ; Cooling system, coolant; Draining and filling
cooling system .
– Install coolant changeover valve 1 - N632- -arrows- ⇒ Rep.

gr. 19 ; Coolant pump, regulation of cooling system; Removing
and installing coolant valve .
– Push on electrical connector -1-.
– Install sump ⇒ page 16 .
– Fill gear oil via oil filler plug for mechatronic unit area
⇒ page 71
DANGER!

– Carry out Basic setting ⇒ Vehicle diagnostic tester.

Torque settings
♦ ⇒ “1.1 Assembly overview - mechatronic unit”, page 15

2 Selector mechanism
⇒ “2.1 Assembly overview - selector mechanism”, page 23
⇒ “2.2 Emergency release from position P”, page 26
⇒ “2.3 Removing and installing selector lever handle”,
page 27
⇒ “2.4 Moving push-button in the handle to installation position”,
page 30
⇒ “2.5 Removing and installing selector mechanism”, page 31
⇒ “2.6 Removing and installing gear selector cable”, page 38
⇒ “2.7 Checking selector mechanism”, page 44
⇒ “2.8 Checking and adjusting selector lever cable”, page 47
⇒ “2.9 Renewing selector shaft seal”, page 49
2.1 Assembly overview - selector mecha‐

nism
2.1.1 Assembly overview- selector mechanism, Golf 2013 ►, Golf 2017 ►
1 - Handle with selector cover

❑ Do not remove handle
without reason. For
emergency release, on‐
ly the cover needs to be
unclipped.
2 - Selector mechanism
❑ With integrated selector
lever - E313- with selec‐
tor lever sensors control
unit - J587- , selector
lever locked in position
P switch - F319- and se‐
lector lever lock sole‐
noid - N110-
3 - Bolt
❑ Qty. 4
❑ 8 Nm
4 - Plug
5 - Retaining clip
❑ Always renew after re‐
moving.
6 - Hexagon flange nut
❑ Qty. 4
❑ 8 Nm
7 - Selector housing
8 - Bolt
❑ Qty. 3
❑ For selector cable sup‐
2. Selector mechanism 23
port bracket to gearbox

❑ 20 Nm
9 - Cable support bracket
❑ For selector lever cable
10 - Gearbox
❑ 20 Nm
12 - Gearbox selector lever
13 - Securing clip
14 - Retaining clip
15 - Selector lever cable
❑ Selector lever cable is not greased
❑ Checking and adjusting

2.1.2 Assembly overview- selector mechanism, Passat 2015 ►, Passat estate

2015 ►
1 - Handle with selector cover

❑ Do not remove handle
without reason. For
emergency release, on‐
ly the cover needs to be
unclipped ⇒ page 26 .
⇒ page 27
2 - Bolt
❑ Qty. 4
❑ 8 Nm
3 - Selector mechanism
❑ With integrated selector
lever sensor control unit
- J587- with selector lev‐
er - E313- , Tiptronic
switch - F189- , switch
for selector lever locked
in P - F319- and selector
lever lock solenoid -
N110-
⇒ page 31
4 - Selector lever cable
❑ Selector lever cable is
not greased
⇒ page 38
❑ Checking and adjusting
⇒ page 47
5 - Retaining clip
❑ Always renew after re‐
moving.
❑ Qty. 4
❑ 8 Nm
7 - Selector housing
❑ Available only together with selector mechanism ⇒ Electronic parts catalogue (ETKA)
8 - Cover
❑ Always renew after removing.
9 - Bolt
❑ Qty. 3
❑ For selector cable support bracket to gearbox
❑ 8 Nm
10 - Cable support bracket
❑ For selector lever cable
11 - Gearbox
❑ 20 Nm
13 - Gearbox selector lever

14 - Securing clip
15 - Bolt
❑ Adjuster screw for selector lever cable
❑ 13 Nm
16 - Retaining clip
2.2 Emergency release from position P
Note
♦ The selector lever cannot be moved out of “P” position when

the battery is disconnected or flat. In this case, the vehicle
cannot be pushed or towed.
♦ If the emergency release is operated, the selector lever lock
solenoid - N110- releases the lock when the vehicle is de-
energised.
2.2.1 Emergency release from position P,

Golf 2013 ►, Golf 2017 ►
Do not remove handle
– Depress brake pedal or set handbrake.
– Open lid of storage compartment.
– Grasp under the cover with one hand and unclip selector cover
by pulling it upwards.

– Push selector cover to one side, press onto the yellow plastic
component and hold it in this position.
Selector lever can now be moved from position »P«.
2.2.2 Emergency release from position P,

Passat 2015 ►, Passat Variant 2015 ►
Do not remove handle
– Depress brake pedal or set handbrake.
– Grasp under the cover with one hand and unclip selector cover
by pulling it upwards.
– Push selector cover to one side.
– Using a screw driver, from right side, press yellow plastic part
and hold in this position.
Selector lever can now be moved from position »P«.
2.3 Removing and installing selector lever

handle
♦ Hose clip pliers - V.A.G 1275 A-
Brief description
Handle is removed together with selector cover.
Removing
– Shift selector lever to position “D”.
The push button -arrow- does not need to be pulled out by hand.
Push button engages automatically in installation position when
handle is pulled off.
– Grasp below cover with one hand and pull it upwards to unclip
it.
– Disconnect electrical connectors.

– Cut open clamp -arrow- under boot using side cutters.

– Pull handle upwards off selector lever without pressing push
button.
Note
Do not press button again after removal as it will otherwise no

longer be possible to install the handle.
Installing
• Selector lever is in position “D”.
Note
♦ It might be possible for the button to be pressed into the han‐

dle. Never install a handle with the button pressed in.
♦ Move push-button to installation position ⇒ page 30 .
♦ New handle is supplied with installation guard. Do not remove
guard until just before installing. To remove, pull out
-in direction of arrow-.
– Push on handle with new clamp -arrow- to stop.

– Secure clip with hose clip pliers - V.A.G 1275 A- .
– Connect electrical connector.
– Push button after installation.
Note
If not installed correctly, the button remains inserted in the handle

after being pressed. If this happens, remove handle again and
move push-button to installation position again ⇒ page 30 .
Then, fit the handle again.
– Clip cover in position.

– Check selector mechanism ⇒ page 44 .
2.4 Moving push-button in the handle to in‐

stallation position
♦ Release tool - T10534-
If the button was pressed by mistake, the installation position can

be restored.
There are 2 ways of moving the push button into the installation
position, »with« and »without« release tool - T 10534- . Both of
them are described here.
Placing handle »with« release tool - T10534- in installation posi‐
tion:
Instead of the release tool - T10534- , the installation guard which
is delivered with new handles may also be used.
When using the installation guard, make sure that it has an eyelet
-arrow- at the front. Other types of installation guard are not suit‐
able.

– Holding down push button, completely push in release tool -

T10534- installation guard with eyelet -arrow-. The installation
guard latches in place while doing so.
– Now, release push button. When the installation guard is
pulled out, the push button engages in installation position.
Placing handle »without« release tool - T10534- or installation
guard in installation position:
– Carefully unclip handle trim -A- upwards.
– Using e.g. a screwdriver press small lever -1- for pull rod into
groove -2-. This action presses the push button -3- back into
installation position.
-I- = button pressed in
-II- = button in installation position
Note
♦ Only press the lever into the groove and no further.

♦ Do not clip the handle trim onto selector mechanism until the
handle has been fitted. This makes it possible to check wheth‐
er the small lever engages in the pull rod when the push-button
is pressed.
2.5 Removing and installing selector mech‐

anism
2.5.1 Removing and installing selector mech‐

anism with selector lever cable
Removing
– Remove selector lever handle ⇒ page 27 .
– Remove centre console ⇒ General body repairs, interior; Rep.

gr. 68 ; Centre console; Removing and installing centre con‐
sole .
– Remove centre console air duct, if fitted ⇒ Heating, air con‐
ditioning; Rep. gr. 87 ; Air duct; Assembly overview - air
routing and air distribution in passenger compartment .
– If fitted, remove mounting bracket -2-. To do this, unscrew
bolts -1- on right and left.
– Separate electrical connector from selector mechanism to ve‐
hicle wiring harness.
– Remove engine cover panel ⇒ Rep. gr. 10 ; Engine cover
panel; Removing and installing engine cover panel .

– Detach coolant expansion tank -1- from bracket, using a small
screwdriver -arrow- to release catches -2-.
– Unscrew nuts -2-, and remove bracket -1-.

– Pull off securing clip -2-.

The securing clip for the selector lever cable must always be re‐
newed.
– Unclip securing clip -1-, and remove it.
– Press selector lever cable off gearbox selector lever.
Caution
Risk of damage to selector lever cable.

♦ Do not push selector lever cable backwards out of cable
support bracket. The selector lever cable is not detached
from the cable support bracket until the selector mecha‐
nism is removed.
♦ Do not bend or kink gear selector cable.
– Remove rear part of exhaust system ⇒ Rep. gr. 26 ; Exhaust

system/silencer; Assembly overview - silencers .
– Remove heat shield for centre tunnel below selector mecha‐
nism ⇒ General body repairs, exterior; Rep. gr. 66 ; Mould‐
ings/trims/extensions; Assembly overview - heat shield .
– If fitted, remove bracket -A-.

– Remove nuts -arrows- inside vehicle.
– Remove selector mechanism -B- together with selector lever
cable and selector housing downwards.
Installing
Caution

– Install heat shield beneath selector mechanism ⇒ General

body repairs, exterior; Rep. gr. 66 ; Underbody cladding; As‐
sembly overview - underbody cladding .
– Install rear section of exhaust system ⇒ Rep. gr. 26 ; Exhaust
pipes/silencers; Assembly overview - silencer .
– Install centre console air duct, if previously removed ⇒ Heat‐
ing, air conditioning; Rep. gr. 87 ; Air duct; Assembly overview
- air routing and air distribution in passenger compartment .
– Install centre console ⇒ General body repairs, interior; Rep.
sole .
– Install selector lever handle ⇒ page 27 .
– Adjust selector lever cable ⇒ page 47 .
– Check selector mechanism and ignition key removal lock
⇒ page 44 .
Torque settings
♦ ⇒ “2.1 Assembly overview - selector mechanism”, page 23

anism without selector lever cable, Golf
2013 ►, Golf 2017 ►
Removing
sole .
– Shift selector lever on selector mechanism to position “N”. On‐
ly in this position the selector lever cable can be released.
– Remove heat shield for centre tunnel beneath selector mech‐
anism ⇒ General body repairs, exterior; Rep. gr. 66 ; Under‐
body cover; Assembly overview - underbody cover .
– Remove plug and securing clip -arrow-.

Always renew securing clip.
– Fit a large screwdriver in grooves of locking element and turn

it 90° in direction of arrow.
– Pull selector lever cable out of selector mechanism.


– Remove selector mechanism -B- together with selector hous‐
ing downwards.
Installing
Note

♦ Do not grease selector lever cable.
♦ Following installation of selector mechanism, selector lever
cable must be checked for ease of movement and be adjusted.
• Selector lever on selector mechanism must be set to position

“N”. Only in this position the selector lever cable can be en‐
gaged.
– Insert selector lever cable into selector mechanism until it is

visible in locking mechanism -arrow-.

– The selector lever cable is properly engaged when the

grooves in the locking element are at right angles to the se‐
lector lever cable.
– Install new securing clip -arrow- and insert plug.

sole .
⇒ page 44 .
Torque settings

anism without selector lever cable, Pas‐
sat 2015 ►, Passat Variant 2015 ►
Removing
sole .

– Using a screwdriver lever the cover off from under the selector
mechanism -arrow-.
Note
It is not permissible to reuse the cover. Always renew after re‐

moving.
– Release the cable as shown with a screwdriver, and pull off

from the selector lever -arrows-.
– Remove securing clip -arrow-.


– Remove selector mechanism -B- together with selector hous‐
ing downwards.
Installing
Note

♦ Following installation of selector mechanism, selector lever
cable must be checked for ease of movement and be adjusted.
♦ Securing clips and covers which have been removed cannot
be reinstalled. Always install new parts.

gaged.
• Insert cable into selector mechanism, attach to selector lever
and fit new securing clip.
– Clip new cover into selector mechanism.
sole .
⇒ page 44 .
Torque settings
2.6 Removing and installing gear selector

cable
2.6.1 Removing and installing final drive, Golf

2013 ►, Golf 2017 ►
Removing



newed.
Caution

nism is removed.

– Remove plug and securing clip -arrow-.


– Pull cable out of selector mechanism and remove.
Installing
Note

♦ Ensure that selector lever cable moves freely after installing.

gaged.
– Insert selector lever cable into selector mechanism until it is

visible in locking mechanism -arrow-.


– The selector lever cable is properly engaged when the

grooves in the locking element are at right angles to the se‐
lector lever cable.
– Install new securing clip -arrow- and insert plug.
– Connect cable to gearbox, and secure it with new securing clip

-2-. Do not install securing clip -1- yet. It is installed only after
the cable has been checked and adjusted.
sole .
2.6.2 Removing and installing selector lever

cable, Passat 2015 ►, Passat Variant
2015 ►
Removing


newed.
Caution

nism is removed.


– Using a screwdriver lever the cover off from under the selector
mechanism -arrow-.
Note
It is not permissible to reuse the cover. Always renew after re‐

moving.
– Release the cable as shown with a screwdriver, and pull off

from the selector lever -arrows-.
– Remove securing clip -arrow-.

Installing
Install in reverse order of removal. Observe the following when
doing this:
Note

♦ Ensure that selector lever cable moves freely after installing.
♦ Securing clips and covers which have been removed cannot
be reinstalled. Always install new parts.

“N”.
– Connect cable to gearbox, and secure it with new securing clip

-2-. Do not install securing clip -1- yet. It is installed only after
the cable has been checked and adjusted.
sole .
2.7 Checking selector mechanism

Overview:
♦ 1. Checking function of selector mechanism ⇒ page 44
♦ 2. Checking ignition key removal lock ⇒ page 45
♦ 3. Checking locking interlock ⇒ page 46
♦ 4th Checking interlock button on selector lever handle
⇒ page 46
♦ 5th Checking connectors on selector mechanism
⇒ page 47
1. Checking function of selector mechanism
• It should not be possible to operate the starter while the se‐
lector lever is in positions “D/S”, “R” or in the “Tiptronic gate”.
• When the vehicle is moving at speeds above 5 km/h and the
selector lever is shifted to position “N”, the solenoid for selector
lever lock must not engage and block selector lever. Selector
lever can be shifted into a driving range.
• When the vehicle is moving at speeds below 2 km/h (almost
stationary) and the selector lever is shifted to position “N”, the
solenoid for selector lever lock should only engage after about
1 second. Selector lever cannot be shifted out of “N” position
until brake pedal is depressed.
Selector lever in position “P”:
– Pull parking brake button to activate the electromechanical
parking brake.
– Switch off ignition.
• Selector lever is locked and cannot be shifted out of “P” posi‐
tion with the lock button pressed on selector lever handle.
– To set the “ignition on” position briefly tap on ignition key in
ignition lock or on entry and start authorisation button - E408- .
– Do not operate brake pedal.
• Selector lever is locked and cannot be shifted out of “P” posi‐
tion with the lock button pressed on selector lever handle.
Solenoid for selector lever lock - N110- blocks selector lever.

– Press brake pedal and keep it pressed down.

• Solenoid for selector lever lock - N110- releases selector lever.
It is possible to shift into a driving gear. With lock button press‐
ed on selector lever handle, slowly shift selector lever from “P”
through “R, N, D/S”; when doing this, check whether selector
lever position display - Y6- in dash panel insert matches se‐
lector lever position.
– Pull selector lever from “D/S” position towards rear, and re‐
lease selector lever again.
• The selector lever returns automatically to selector lever po‐
sition “D/S”. The selector lever position display - Y6- in the
dash panel insert must change from “D” to “S1” and change
back to “D” after the selector lever has been pulled back again.
Selector lever in “N” position and ignition switched on:
• After a short period, the selector lever is locked and cannot be
shifted out of “N” position, although the lock button on the se‐
lector lever handle is pressed. Solenoid for selector lever lock
- N110- blocks selector lever.
– Operate brake pedal.
• Solenoid for selector lever lock - N110- releases selector lever.
Selector lever can be shifted to “D/S” position.
Selector lever in “D/S” position, ignition switched on:
– Shift selector lever into “Tiptronic gate”.
• The illuminated “D/S” symbol in the selector lever position dis‐
play - Y26- should go out and the “+” and “–” symbols should
light up.
• The selector lever position display - Y6- in the dash panel in‐
sert must change from “D” to “M1” when selector lever is
shifted into the “Tiptronic gate”.
If specifications are not attained:
– Find the fault ⇒ Vehicle diagnostic tester, Guided fault
finding .

– Check lock button on selector lever handle ⇒ page 46 .
2. Checking ignition key removal lock
– Pull parking brake button to activate the electromechanical
parking brake.
– To set the “ignition on” position briefly tap on ignition key in
ignition lock.
– Press brake pedal and keep it pressed down.
• When the lock button in the selector lever handle is pressed,
it must be possible to move the selector lever out of position
“P” without “catching”.
• It must be possible to remove the ignition key only in selector
lever position “P”.
– Switch selector lever to “P” position.
– Pull out ignition key.
• It must be possible to remove the ignition key only in selector

lever position “P”.
• The selector lever is locked and cannot be shifted out of “P”
position with the lock button pressed and the brake pedal de‐
pressed.
If the ignition key removal lock does not work as described:
finding .
3. Checking locking interlock - vehicles with keyless access lock‐

ing and starting system
– To set the “ignition on” position briefly tap on entry and start
authorisation button - E408- .
– Do not shift selector lever to position “P”. Instead shift it to
position “N”, for example.
• A warning must be displayed in the dash panel insert.
• The vehicle cannot be locked.
– Switch on ignition, and move selector lever to position “P”.
• The vehicle can be locked.
finding .

– Check lock button on selector lever handle ⇒ page 46 .
4th Checking interlock button on selector lever handle
Checking whether lock button is free to move:
• It must be possible to press the lock button without using ex‐
cessive force.
• After the lock button has been released, it must return to its
original position completely and autonomously.
– If the specifications are not attained, check whether the se‐
lector lever handle is installed correctly ⇒ page 27 .
– Check whether the selector lever is bent.
Functional check:
• Ignition switched on
The lock button on the selector lever handle must be pushed for
the following shift operations, or if the lock button is not pushed,
it must not be possible to shift the selector lever to the respective
positions.
♦ “P” to “R”, depress brake pedal in addition
♦ “N” to “R”, as soon as the vehicle has stopped, after a longer
period depress brake pedal in addition
♦ “R” to “P”
– Check whether the selector lever handle is installed correctly
⇒ page 27 .

– Check connectors on selector mechanism.

– Check selector lever lock solenoid - N110- ⇒ Vehicle diag‐
nostic tester, Guided fault finding .
5th Checking connectors on selector mechanism
Before repairing or checking connectors, check whether there are
entries stored in the event memory for any of the control units in
the vehicle ⇒ Vehicle diagnostic tester, Guided fault find-
ing . If necessary, rectify any faults.
– Check connectors ⇒ Current flow diagrams, Electrical fault

finding and Fitting locations.
1- Connector for wires from shift unit to gearbox (with CAN bus
wire) and to selector lever lock solenoid - N110- and selector
lever locked in position P switch - F319-
2- Electrical connector for selector lever position display - Y26-
2.8 Checking and adjusting selector lever

cable
Test conditions
• Selector mechanism and selector lever cable glide easily
when changing gear.
• Rubber grommet of selector lever cable undamaged.
Adjusting selector lever cable
The selector lever cable must be adjusted if
♦ The selector lever cable has been removed from the gearbox.
♦ The engine and/or gearbox has been removed and installed.
♦ Selector lever cable with selector mechanism has been re‐
moved and installed.
♦ The selector lever cable has been removed and installed.
♦ The position of the engine and gearbox is shifted, for example
to install it free of tension.
– Switch selector lever to “P” position.

– Push coolant hoses to one side.

– Loosen adjustment screw -arrow- for selector lever cable.

– Shift gearbox selector lever on gearbox to position “P”. To
check, push gearbox selector lever opposite to driving direc‐
tion to rear stop.
Note
Raise vehicle, to be sure that the gearbox is in “P” (parking lock

engaged). It should not be possible to turn both front wheels to‐
gether in the same direction.
– To release tension from selector lever cable move selector

lever slightly forwards and backwards, but do not shift it to an‐
other selector lever position.
– Tighten adjustment screw -arrow-. The position of the selector
lever cable must not change while doing so.
Specified torque: 12Nm
Checking adjustment of selector lever cable
– Keep button pressed, while pulling selector lever approx.
5 mm to the rear out of position “P”. Then keep lever in this
position, do not move it into “R”.
– Release selector lever.
• The selector lever must return to position “P” autonomously.
– Move selector lever to position “N”.
– Keep button pressed, while pulling selector lever approx. 5
mm to the rear out of position “N”. Then keep lever in this po‐
sition, do not move it into “D/S”.
• The selector lever must return to position “N” autonomously.
– Keep button pressed, while pushing selector lever approx.
5 mm to the front out of position “N”. Then keep lever in this
position, do not move it into position “R”.
• The selector lever must return to position “N” autonomously.
– If the selector lever does not work as described, repeat ad‐
justment:
2.9 Renewing selector shaft seal

• Gearbox is installed.
DANGER!


– Drain coolant from engine and high-voltage system ⇒ Rep.
gr. 19 ; Cooling system/coolant; Draining and filling coolant .

– Lift retaining clip -1-, release hose clip -2-, disconnect coolant
hoses, and push them to one side.
Note
♦ For reasons of clarity, the illustration shows the installation

position with high-voltage components removed.
♦ Disregard -item 3-.
– Release hose clips -arrows-, remove coolant hoses, and push

them to one side.

Caution

support bracket.
– Unscrew nut -1-.

– Carefully lever gearbox selector lever -2- off selector shaft.
Caution
Risk of damage to contact surface of selector shaft.

♦ Fit screwdriver carefully.
– Using a small screwdriver, pierce through seal and pull it out.
– Fill half of the space between sealing lip and dust lip -arrow-
with sealing grease ⇒ Electronic parts catalogue .
– Drive in new seal to stop using 15 mm socket -item 1-, being

careful not to cant seal.
• Closed side of oil seal -arrow- faces towards outside.
– Fit gearbox selector lever -2- onto selector shaft, and tighten
nut -1-.
• The gearbox selector lever fits on splines in only one position.
– Push selector lever onto gearbox selector lever, and adjust
selector lever cable ⇒ page 47 .
DANGER!


Torque settings

3 Removing and installing gearbox

⇒ “3.1 Removing gearbox”, page 53
⇒ “3.2 Installing gearbox”, page 53
⇒ “3.3 Specified torques for gearbox”, page 54
3.1 Removing gearbox

Brief description
The gearbox cannot be removed individually. It is removed down‐
wards together with the engine using the scissor-type assembly
platform. Then, the gearbox is separated from the engine.
Removing:
– Remove engine with gearbox ⇒ Rep. gr. 10 ; Removing and
installing engine .
– Separate engine and gearbox ⇒ Rep. gr. 10 ; Removing and
installing engine; Separating engine and gearbox .
Transporting gearbox ⇒ page 56 .
Install gearbox ⇒ page 53 .
3.2 Installing gearbox

Note
♦ Refer to procedure “Removing gearbox” ⇒ page 53 for re‐

quired special tools.
♦ Renew bolts that are tightened with turning further angle.
♦ Renew all removed cable ties, and fit them in the original po‐
sition when installing.
– Place gearbox on scissor-type assembly platform.
3. Removing and installing gearbox 53

– Check that there are dowel sleeves -A- for centring engine and
gearbox fitted in the cylinder block. Insert any missing dowel
sleeves.
– Tighten gearbox to engine.
Note
♦ It must be possible to guide the engine and gear box together

by hand until the flanges make contact all around.
♦ Otherwise, readjust the gearbox support until engine and
gearbox are properly aligned with each other.
– Install drive shaft ⇒ Running gear, axles, steering; Rep. gr.

40 ; Drive shaft; Removing and installing drive shafts .
– If present, install heat shield above right drive shaft ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and
installing drive shaft .
– Install selector lever cable on dual clutch gearbox
⇒ page 31 .
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
DANGER!


– Check coolant level ⇒ Rep. gr. 19 ; Cooling system, coolant;
Draining and filling coolant .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Assembly overview - noise insula‐
tion .
3.3 Specified torques for gearbox

Gearbox to engine:
Item Bolt Nm
1, 5, 9 M12×70 80
2, 3 M12x60 80
4 M12x50 1) 80
6, 7, 8 M10x50 40
A Dowel sleeves for centring
• 1) Centre hex stud

4 Assembly mountings
⇒ “4.1 Assembly overview - assembly mountings”, page 55
4.1 Assembly overview - assembly mountings
1 - Engine support
⇒ Rep. gr. 13 ; Cylinder
block, pulley end; Re‐
moving and installing
engine support
2 - Engine mounting
❑ With support arm
⇒ Rep. gr. 10 ; Assem‐
bly mountings; Remov‐
ing and installing engine
mounting
3, 4, 5 - Bolt
❑ Specified torque ⇒ Rep.
gr. 10 ; Assembly
mountings; Assembly
overview - assembly
mountings
6 - Bracket
❑ Version
7, 8, 9 - Bolt
❑ Specified torque ⇒ Rep.
gr. 10 ; Assembly
mountings; Assembly
overview - assembly
mountings
10 - Pendulum support
⇒ Rep. gr. 10 ; Assem‐
bly mountings; Remov‐
ing and installing pendu‐
lum support
11, 12, 13 - Bolt
❑ Specified torque ⇒ Rep. gr. 10 ; Assembly mountings; Assembly overview - assembly mountings
14 - Bolt
❑ Renew
❑ 60 Nm +90°
15 - Bolt
❑ Renew
❑ 50 Nm +90°
16 - Gearbox mounting
❑ Removing and installing ⇒ Rep. gr. 10 ; Assembly mountings; Removing and installing gearbox mounting
4. Assembly mountings 55
5 Transporting gearbox
♦ Lifting tackle - 2024A-
♦ Workshop hoist - VAS 6100-
– Attach lifting tackle - 2024A- to gearbox lifting eyes, and se‐
cure it with locking pins -arrows-.
– Attach workshop hoist - VAS 6100- to lifting tackle - 2024A- .
Caution
Risk of damage to gear oil cooler during transport.

♦ Guide gearbox during transport.

6 Gear oil circuit

⇒ “6.1 Assembly overview - gear oil circuit”, page 57
⇒ “6.2 Removing and installing gear oil cooler”, page 57
⇒ “6.3 Removing and installing gear oil filter”, page 59
6.1 Assembly overview - gear oil circuit
1 - Bolts
❑ 8 Nm +90°
2 - Connection
3 - O-ring
4 - Gearbox
5 - O-ring
6 - Bolt
❑ 20 Nm +45°
7 - Gear oil cooler
⇒ page 57
8 - O-ring
9 - Filter element
⇒ page 59
❑ With O-ring on intake
collar
❑ Renew O-ring after
each removal
10 - O-ring
11 - Filter housing
⇒ page 59
❑ 50 Nm
6.2 Removing and installing gear oil cooler

6. Gear oil circuit 57

♦ Hose clamps to 25 mm - 3094-
♦ Hose clamp pliers - VAS 6340-
Removing
DANGER!


– Remove power and control electronics for electric drive - JX1-
⇒ Rep. gr. 93 ; Power and control electronics for electric drive;
Removing and installing power and control electronics for
electric drive .
WARNING
Danger of scalding due to steam and hot coolant.

♦ On a warm engine, the cooling system is under high pres‐
sure.
♦ Reduce excess pressure by covering the cap of the cool‐
ant expansion tank with cloths and opening it carefully.
– Open filler cap -arrow- on expansion tank.

Note
Place a cloth underneath to catch escaping coolant.
– Clamp off coolant hoses on gear oil cooler using hose clamps
-3094- .
– Release hose clips -1, 2-, and remove coolant hoses.
– Unscrew bolts -arrows-, and remove gear oil cooler.
Caution
Risk of contamination of gear oil.

♦ No coolant must be allowed to drip into the gearbox!
Installing
Note
♦ Renew bolts for gear oil cooler after each removal.

♦ Renew O-rings after each removal.
– Install power and control electronics for electric drive - JX1- ⇒

Rep. gr. 93 ; Power and control electronics for electric drive;
Removing and installing power and control electronics for
electric drive .
DANGER!


– Check coolant level ⇒ Rep. gr. 19 ; Cooling system, coolant;
Draining and filling coolant .
Torque settings
♦ ⇒ “6.1 Assembly overview - gear oil circuit”, page 57
6.3 Removing and installing gear oil filter

The gear oil filter must be renewed under the following conditions:
♦ Coolant got into the gear oil.
♦ Metal particles have been found in the gear oil.
♦ The clutch is burnt or has a mechanical defect.
6. Gear oil circuit 59

Removing
• Gearbox is removed.
Caution
Risk of soiling caused by escaping gear oil.

♦ A residual amount of gear oil remains in the oil filter. It runs
out when filter housing is unscrewed.
♦ Before unscrewing the filter housing, cover the area
around the gear oil filter with a sufficient number of cloths.
♦ Thoroughly clean oily areas on gearbox.
– Unscrew filter housing -arrow-, and remove filter element.
Installing
Note
Renew O-ring after each removal.
– Insert filter element with intake collar -arrow- into gearbox.

– Tighten filter housing.
– Following installation of gearbox, check gear oil level
⇒ page 61 .
Torque settings

7 Gear oil
⇒ “7.1 Overview of fitting locations - oil drain and inspection
plugs”, page 61
⇒ “7.2 Checking gear oil level”, page 61
⇒ “7.3 Draining and filling gear oil”, page 67
⇒ “7.4 Filling with gear oil after mechatronic unit has been re‐
newed”, page 71
7.1 Overview of fitting locations - oil drain and inspection plugs
1 - Plug
❑ For filler and inspection
hole
❑ 45 Nm
2 - Seal
3 - Overflow pipe
❑ 3 Nm
4 - Seal
5 - Plug
❑ For filler hole of oil
space for mechatronic
unit
❑ 20 Nm
6 - Seal
7 - Plug
❑ For drain hole of oil
space for mechatronic
unit
❑ 20 Nm
8 - Seal
9 - Plug
❑ For drain hole of gear‐
box
❑ 45 Nm
7.2 Checking gear oil level

7. Gear oil 61
♦ Oil filling adapter - VAS 6262 A- with adapter - VAS 6262/1-
♦ Vehicle diagnostic tester

♦ Safety glasses
♦ Acid-resistant protective gloves
♦ For some oil bottles adapter - VAS 6262/6- must be used as
well.
Please follow instructions:
♦ If gear oil is being added, use only oil listed as a replacement
part in ⇒ Electronic parts catalogue (ETKA) .
♦ Some oil bottles require the use of adapter - VAS 6262/6- as
well.
♦ Breather pipe of adapter for oil filling - VAS 6262 A- may need
to be shortened ⇒ page 63 .

Measure length of breather pipe attached to adapter for filling oil

- VAS 6262 A- and shorten as necessary.
In order to ensure that the breather pipe of the -VAS 6262 A-
adapter for oil filling does not touch the bottom of some oil bottles,
the pipe must be shortened to the length -a-.
• Dimension -a- = 210 mm
Note
The dimension -a- is measured from the shaft (green area in the
magnifying glass) of the adapter for oil filling -VAS 6262 A- .
7. Gear oil 63
– Mark dimension on the breather pipe and shorten pipe with

pipe cutter -6056/2- .
– Clean adapter for filling oil - VAS 6262 A- .
Note
Observe rules for cleanliness ⇒ page 10 .
WARNING
Risk of injury.
♦ Wear safety goggles.
♦ Wear acid-resistant gloves
♦ When working in the vicinity of the radiator, always make
sure to keep sufficient clearance to the fan since it may be
switched on unexpectedly.
Risk of accident by accidentally engaging a gear while the en‐
gine is running.
♦ Before work is done with the engine running, move the
selector lever to the “P” position, and pull the parking brake
button, to activate the electromechanical parking brake.
Caution

♦ It is not permissible to start the engine if there is an insuf‐
ficient amount of gear oil or no gear oil in the gearbox after
repair work or after large amounts of gear oil have esca‐
ped.
♦ After repair work or after large amounts of gear oil have
escaped, prefill the gearbox with gear oil.
the 6-speed dual clutch gearbox 0DD; for allocation refer
to ⇒ Electronic parts catalogue .
box.
♦ The adapter for oil filling - VAS 6262 A- must be clean, and
it must be ensured that the gear oil is not mixed with any
other oils!
Test conditions
• Gearbox not in emergency running mode.
• Vehicle level, all supports in lifting platform at same height.
• Selector lever in position “P”.
• The parking brake button has been pulled to activate the elec‐
tromechanical parking brake.
• The extraction hoses of a switched-on exhaust extraction sys‐
tem are connected.
• Engine is not running.

Reading gear oil temperature
Note
♦ The gear oil level changes depending on the gear oil temper‐
ature: if the gear oil temperature is too low, too much gear oil
may be filled; if the gear oil temperature is too high, an insuf‐
ficient amount of gear oil may be filled.
♦ An improper gear oil level impairs the function of the gearbox.
♦ At start of work, the oil temperature must not be above 30°C.
If necessary, allow the gearbox to cool down.
♦ Test temperature: 20 … 40°C
– Connect ⇒ Vehicle diagnostic tester to the vehicle and start

the diagnose mode.
♦ Select Own test
♦ 02 - Gearbox electronics, functions
♦ 02 ATF level ⇒ Check ATF level
• Specification at start of test: not higher than 30°C, otherwise
allow the gearbox to cool down.
Checking gear oil level
insulation .
low gearbox.
– Remove plug -1- with seal -2-. The overflow pipe -3- remains
fitted.
Renew seal -2- for plug after removal.
Note
♦ Even if oil level is too low, a small amount of oil will initially run
out of oil overflow pipe because pipe fills up during operation.
♦ Irrespective of the gear oil level a small gush of oil escapes
from the overflow pipe every 30 seconds due to the cooling oil
pulses for supplying the multi-clutch. This is not relevant for
determining the gear oil level.
♦ Gear oil which has escaped must not be reused.
7. Gear oil 65
• The accumulated gear oil flows out of the overflow pipe

-arrow 2-.
– Let surplus oil flow out.
– After excess oil has run out (starts to drip), install plug with new
seal.
– Top up oil if no oil flows out.
Topping up gear oil
– Screw adapter - VAS 6262/1- hand-tight into filler and inspec‐

tion hole -1-.
– Shake bottle before opening.
– Screw adapter for oil filling - VAS 6262 A- onto oil bottle. Before
doing this, observe following notes ⇒ page 62 .
– Top up with oil.
– Pull adapter for oil filling - VAS 6262- off quick-release cou‐
pling at regular intervals and check:
If oil now flows out of hole in adapter:
Oil does not need topping up.
– Allow surplus oil to drain out.
– After excess oil has run out (when it begins only to drip), re‐
move adapter for filling oil - VAS 6262 A- and install plug with
new seal.
If no oil drips out of inspection hole:
– Top up with oil ⇒ page 66 .
WARNING
An oil level which is too low or too high will impair the function
of the gearbox.

When the oil level is correct, screw in plug with new seal -arrow-
and tighten.
Torque settings
– Unscrew adapter for oil filling - VAS 6262 A- from gearbox.
– Tighten plug -1-.

– Switch off ignition and separate diagnosis connections.
Torque settings
♦ ⇒ “7.1 Overview of fitting locations - oil drain and inspection
plugs”, page 61
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Assembly overview - noise insulation .
7.3 Draining and filling gear oil

♦ Oil filling adapter - VAS 6262 A- with adapter - VAS 6262/1-
♦ Vehicle diagnostic tester

♦ Safety glasses
7. Gear oil 67
Some oil bottles require the use of adapter - VAS 6262/6- as well.
Note
WARNING
Risk of injury.
gine is running.
Caution

ped.
box.
other oils!

– Measure length of breather pipe on adapter for oil filling - VAS

6262 A- , and shorten it as necessary ⇒ page 63 .
Test conditions
• Gearbox not in emergency running mode.
• Vehicle is placed on a four-pillar lifting platform or above an
assembly pit to ensure it is in total horizontal position.
• Selector lever in position “P”.
• The parking brake button has been pulled to activate the elec‐
tromechanical parking brake.
• Engine is not running.
Drain gear oil
the diagnose mode.
♦ Select Own test
♦ 02 - Gearbox electronics, functions
♦ 02 ATF level ⇒ Drain ATF
– Follow the instructions on the display.
Note
The function “drain ATF” blocks the high-pressure pump of the

mechatronic unit and the pressure reservoir is drained.

insulation .
low gearbox.
– Remove plugs -1 and 2-.
– Unscrew plug -arrow- of mechatronic unit.
7. Gear oil 69
– Unscrew overflow pipe -3-.

– Drain entire oil.
– Reinstall overflow pipe -3-. Specified torque:
⇒ Item 3 (page 61)
Fill with gear oil
Caution
Risk of gearbox damage.

If the mechatronic unit has been renewed, it is essential to fill
the oil through the oil filler plug for the mechatronic unit
⇒ page 71 .
– Renew seals on all plugs -arrow-.
– Fit and tighten plug -2-. Tighten plug -1- hand-tight first.
Torque settings
♦ ⇒ “7.1 Overview of fitting locations - oil drain and inspection
plugs”, page 61
– Tighten plug -arrow- of mechatronic unit.

– Shake bottle before opening.

– Screw adapter for oil filling - VAS 6262 A- onto oil bottle.
– Unscrew plug -1-.

– Screw adapter - VAS 6262/1- hand-tight into filler and inspec‐
tion hole -1-.
– Connect adapter for oil filling - VAS 6262 A- to adapter - VAS
6262/1- .
– Hold bottle with adapter for oil filling - VAS 6262 A- as high as
possible over the dual clutch gearbox, and allow approx. 5 l of
gear oil to flow into the dual clutch gearbox.
– Then, check oil level and top up as necessary ⇒ page 61 .
7.4 Filling with gear oil after mechatronic

unit has been renewed
♦ Adapter for oil filling - VAS 6262 A- with flexible hose adapter
- VAS 6262/5-
♦ Safety glasses
7. Gear oil 71
Some oil bottles require the use of adapter - VAS 6262/6- as well.
Note
WARNING
Risk of injury.
gine is running.
Caution

ped.
box.
other oils!
– Measure length of breather pipe on adapter for oil filling - VAS

6262 A- ; shorten if necessary ⇒ page 61 .
Condition:
• Bracket for high voltage battery charger is removed ⇒ Rep.
gr. 93 ; Charging unit for high-voltage battery; Removing and
installing charging unit 1 for high-voltage battery - AX4- .

– Plugs -1- and -2- have been installed.
Filling
– Unscrew oil filler plug for mechatronic unit -arrow-.
– Connect adapter for oil filling - VAS 6262 A- to flexible hose
adapter - VAS 6262/5- .
– Guide flexible hose adapter - VAS 6262/5- into oil filler hole.
– Hold bottle with adapter for oil filling - VAS 6262 A- as high as
possible over the dual clutch gearbox, and allow approx. 5 l of
gear oil to flow into the dual clutch gearbox.
– Remove adapter, and tighten plug with new seal. Torque
⇒ page 61
– Install bracket for high voltage battery charger ⇒ Rep. gr. 93 ;
Charging unit for high-voltage battery; Removing and installing
charging unit 1 for high-voltage battery - AX4- .
DANGER!


– Then, check oil level and top up as necessary ⇒ page 61 .
7. Gear oil 73
8 Dismantling and assembling gearbox

⇒ “8.1 System overview - gearbox”, page 74
⇒ “8.2 Assembly overview - gearbox”, page 75
⇒ “8.4 Removing hybrid module”, page 76
⇒ “8.5 Renewing hybrid module”, page 81
⇒ “8.6 Installing hybrid module”, page 86
⇒ “8.7 Removing and installing rotor position sensor and temper‐
ature sender”, page 89
⇒ “8.8 Renewing sealing cap”, page 93
8.1 System overview - gearbox
1 - Hybrid module
❑ Removing ⇒ page 76
❑ Installing ⇒ page 86
2 - High voltage cables
⇒ Engine, mechanicals;
Rep. gr. 93 ; High volt‐
age cables; Removing
and installing high volt‐
age cable set for drive
motor
3 - Gear oil cooler
⇒ page 57
4 - Gear oil filter
⇒ page 59
5 - Gearbox housing
6 - Mechatronic unit
⇒ page 19
7 - Sump
⇒ page 16

8.2 Assembly overview - gearbox
1 - Bolt
❑ 20 Nm + 90°
❑ Renew
2 - Hybrid module
3 - Dowel sleeve
4 - Shim
❑ For differential bearing
5 - Differential bearing
❑ Outer shell
6 - Differential bearing
7 - Seal
❑ Renew
8 - Release bearing
❑ Clutch K1
9 - Shim
10 - Shim
11 - Release bearing
❑ Clutch K2
12 - Cap
13 - Cap
❑ Renewing ⇒ page 93
14 - O-ring
15 - Breather pipe
16 - Threaded pin
❑ 20 Nm
17 - Carbon contact
18 - Cap
19 - Bolt
❑ 10 Nm
❑ Renew
20 - Seal
21 - Ring contact
22 - Bolt
❑ 10 Nm
23 - Cap
24 - O-ring
❑ Renew
25 - Screw plugs
❑ 10 Nm
8. Dismantling and assembling gearbox 75

❑ Renew
26 - O-ring
❑ Renew
27 - O-ring
❑ Renew
28 - Seal
29 - Gearbox housing
8.3 Assembly overview - hybrid module
1 - Connector housing
2 - Hybrid module
3 - Wiring guide
4 - Bolt
❑ 8 Nm + 90°
❑ Renew
5 - Bolt
❑ 8 Nm + 90°
❑ Renew
6 - Drive motor rotor position
sender 1 - G713- with drive
motor temperature sender -
G712-
⇒ page 89
7 - Retaining ring
❑ Renew
8 - Support ring
❑ Renew
9 - Thrust plate K1
10 - Rotor
8.4 Removing hybrid module

♦ Support tool - T10557-
♦ Support - T10556-

♦ Retainer - VW 309-
♦ Engine and gearbox support - VAS 6095-
♦ Workshop hoist - VAS 6100-
♦ Hub grease cap puller - VW 637/2-

Preparing support - T10556/2- :
Note
On some supports - T10556/2- , the two M8 bolts -1- are too long.
Dimension -a- must be approx. 16 mm. In the bolts -1- are longer,
they need to be shortened.
– Shorten both bolts according to dimension -b- using e.g. hack

saw.
• Dimension -b- = 40mm
– Deburr bolt ends.
– Turn spacer sleeve -2- towards end of bolt and back again in
order to remove any swarf.
– Spray bolt ends with rust protector.
Procedure:
– Move lever to position P.
• Moving to the P position engages gears 1 and R. This locks
the gearbox shafts.
– Drain gear oil ⇒ page 67 .
– Remove gearbox ⇒ page 53 .
– Secure support tool - T10557- to gearbox flange -arrows-.

• Specified torque: 30 Nm

– Detach gear oil cooler, loosen hose clips -1, 2-, and unscrew
bolts -arrows-.
– Seal holes in gearbox with sealing plugs.
– Loosen nut -1-, and detach lever for parking lock -2-.
– Remove high-voltage cables ⇒ Engine, mechanical system;
Rep. gr. 93 ; High-voltage cables; Removing and installing
high-voltage wiring harness for drive motor .
Vehicles with pressed-in cap:

– Remove lower sealing cap.
• The sealing cap cannot be removed without it being damaged.
– Punch a hole in the centre of the sealing cap with a screwdriver
and hammer.
– Lever out cover with hub cap puller - VW 637/2- .
Vehicles with threaded cap:

– Remove threaded cap ⇒ page 94 .

Continued for all vehicles:

– Secure support - T10556/2- -A- to holes for gearbox mounting
-arrows-.
• Screw in the two bolts alternately to prevent the plate from
canting.
• Specified torque: 50 Nm
– Secure support - T10556/1- -B- to support plate - VW 309-

-C-, and secure it through holes for gear oil cooler -arrows-.
• Specified torque: M8 30 Nm
• Specified torque: M12 50 Nm
– Secure hook of workshop hoist - VAS 6100- to eye of support

tool - T10557- , raise gearbox to vertical position, and attach
it to engine and gearbox support - VAS 6095- .

– Loosen bolts on flange.
– Slowly raise hybrid module using workshop hoist - VAS 6100- .

♦ Shaft for parking lock may be canted slightly. Release it, if
necessary, with light blows against the housing using a plastic
hammer.
– Stow hybrid module: A second mechanic rotates the hybrid
module with the gearbox flange towards the stowage area.
– Slowly lower hybrid module.
– Place suitable wooden blocks or foam pads underneath to
make sure that the hybrid module makes contact evenly all
around.
8.5 Renewing hybrid module

♦ Internal puller - VAS 251 619-

♦ Counter support - VAS 251 625-
♦ Assembly tool - T40342/4-
♦ Nut - T10254/4-
♦ Spindle - T10254/5-
♦ Thrust plate - 3062-
– Remove hybrid module ⇒ page 76

• If the hybrid module is to be renewed, the outer shell of the

differential bearing is required for installation.
Remove outer shell of differential bearing:
– Insert internal puller - VAS 251 619- in bearing shell -1- and
tension.
– Mount counter support - VAS 251 625- .
– Remove bearing shell using spindle.
• If a new hybrid module is installed:

• Renew shims for release bearings of clutches K1 -2- and G2
-4-.
• Renew shim -1- for differential bearing.

Calculating thickness of new shims:

– Measure and note thickness of old shim for differential bear‐
ing: dimension L1old
– Measure and note thickness of old shim for clutch K1 release
bearing: dimension H1old
– Measure and note thickness of old shim for clutch G2 release
bearing: dimension H2old
– Measure and note thickness of old and new flange seal at

three points -arrows-: dimension M1old, M2old, M3old, dimen‐
sion M1new, M2new, M3new.
• Only measure in edge area not via crease.
– Determine mean value of flange seal: dimension M
M = M1+M2+M33
– Note dimension G1, G2, K1 from old and new hybrid module.
• The production dimensions of the hybrid module are engraved
in the housing.
– Calculate thickness of shim for differential bearing:
L1new = K1new — K1old + L1old + Mnew - Mold
– Calculate thickness of shim for clutch K1 release bearing:
H1new = G1old — G1new + H1old + Mnew - Mold
– Calculate thickness of shim for clutch K2 release bearing:
H2new = G2old — G2new + H2old + Mnew - Mold
– Order shims using ⇒ ETKA .

– Insert new shims for clutch release bearing -2 , 4-.

– Align seal -5- centrally on shaft.
Installing outer shell for differential bearing:

– Insert new shim -1- and bearing shell -2-.
– Place thrust plate - T10365/5- on bearing shell.

– Feed in spindle - T10254/5- .
– Place thrust pad - 3062- on outside of housing and secure to
spindle with nut - T10254/4- .
– Slowly and carefully install bearing shell using spindle.
Caution
The bearing shell could cant slightly as it is driven in.

Risk of damage to bearing shell and bearing seat.
Only moderate force is used to drive in the bearing shell.
Should greater force be imparted, the bearing shell will cant.
If the bearing shell is canted, bring it back into position with light
blows of the hammer.
– Install hybrid module ⇒ page 86 .

8.6 Installing hybrid module

♦ Thrust piece - T10143-
♦ Earth cable - VAS 6558A/28-
• If a new hybrid module is installed, additional work will be re‐

quired ⇒ page 81 .
Procedure:
– With the aid of a second mechanic, lift up the hybrid module
from the stowage area and turn it upwards.
– Renew metal gasket ⇒ Item 7 (page 75) on flange.
– Ensure parking lock shaft is seated correctly.
– Slowly place hybrid module onto gearbox with motorised
crane, ensuring clearance to all parts.
• Metal gasket and dowel sleeves in correct position.
• Pin for parking lock in correct position.
• Lever for parking lock in correct position.
• Shaft for parking lock must be free to move.
TIP:

♦ If it proves difficult to locate the clutch on the input shafts

-1 and 2-, turn the input shafts via the lower output shaft bolt
-3-.
– Insert bolts on flange and tighten in the sequence -1 to 25-.

Insulation measurement
To ensure that no high-voltage components on the gearbox are
damaged during work, the insulation must be measured.
– Engage earth wire - VAS 6558A/28- -A- in connector housing
and secure clamp to housing -arrow 4-.
the diagnose mode.
♦ Select Own test
♦ Body
♦ Electrical system
♦ 01 - Self-diagnosis compatible systems
♦ 51 - Electric drive control unit - J841
♦ 51 -Insulation measurement electric drive motor
V141
– Follow instructions on display.

– Install high-voltage cables ⇒ Engine, mechanicals; Rep. gr.
93 ; High-voltage cables; Removing and installing high-voltage
cable set for drive motor
– Renewing selector shaft seal ⇒ page 49 .
– Install parking lock lever.
Vehicles with pressed-in cap:

– Drive in cap at bottom with thrust piece - T10143- until it is
flush.

Vehicles with threaded cap:

– Installing cap ⇒ page 94
Continued for all vehicles:
– Renewing right oil seal ⇒ page 97
– Secure gearbox on gearbox support - T40173- .
– Remove retaining plate - VW309- and adapter from gearbox.
– Install gearbox oil cooler.
– Fill with gear oil ⇒ page 67 .
– Install gearbox ⇒ page 53 .
Recalibration
– Recalibration is required following work on hybrid module.
the diagnose mode.
♦ Select Own test
♦ Body
♦ Electrical system
♦ 01 - Self-diagnosis compatible systems
♦ 51 - Electric drive control unit - J841
♦ 51 - Electric drive, functions
♦ 51 - Calibrate electric drive motor
Specified torques
♦ Specified torques:
♦ ⇒ “8.2 Assembly overview - gearbox”, page 75
8.7 Removing and installing rotor position

sensor and temperature sender
Drive motor rotor position sender 1 - G713- and drive motor tem‐
perature sender - G712-
♦ Removal wedge - 3409-
Removing
– Remove hybrid module ⇒ page 76 .

– Remove wiring harness -2- from cable guide -1-.

– Unscrew bolts -arrows-.
– Remove cable guide -1-.
– Turn connector housing -1- anti-clockwise -arrow B- and re‐

move it.
– Remove connector -2-.
– Remove circlip -1-.

– Lever off support ring -2- evenly using removal wedge - 3409-
and remove.
– Remove pressure plate -1-.

– Lever off rotor -1- evenly using removal wedge - 3409- and
remove.
– Loosen bolts -arrows- and remove drive motor rotor position

sender 1 - G713- -1-.
Installing
– Carefully insert tip of temperature sender in recess between
stator windings.
– Install drive motor rotor position sender 1 - G713- -1- and

tighten bolts -arrows-.

– Carefully and evenly insert rotor -1-.

• If the individual plates of the rotor have worked loose, this must
be renewed.
– Fit pressure plate -1-.
– Fit support ring -2-.

– Install retaining ring -1-.
– Ensure that circlip -1- has correct and even contact.
• Dimension a ≈ 14 mm
– Turn connector housing -1- clockwise -arrow A- and engage.

• Turn approx. 70°.

– Insert cable guide -1- and tighten bolts -arrows-.

– Clip wiring harness -2- in cable guide -1-.
– Install hybrid module ⇒ page 86 .
Torque settings
⇒ “8.3 Assembly overview - hybrid module”, page 76
8.8 Renewing sealing cap

⇒ “8.8.1 Renewing pressed in sealing cap”, page 93
⇒ “8.8.2 Renewing screwed in sealing cap”, page 94
8.8.1 Renewing pressed in sealing cap

♦ Hub grease cap puller - VW 637/2-
The upper sealing cap is renewed in the same manner.

• The sealing cap cannot be removed without it being damaged.

– Punch a hole in the centre of the sealing cap with a screwdriver

and hammer.
– Lever out cover with hub cap puller - VW 637/2- .
– Drive in cap at bottom with thrust piece - T10143- until it is

flush.
8.8.2 Renewing screwed in sealing cap

Sealing cap is installed with slip ring contact depending on design.
♦ Press tool - 30-504-

– Loosen bolts of cap -2- and remove carbon brushes -1-.
– Loosen bolts -arrows- and remove cover -1-.
– Renew O-ring -1- and seal -2-.

– Drive in new oil seal -2- to stop using thrust piece - 30-504-
-A-.
• Open side of seal points towards gearbox
Torque settings

35 – Gears, shafts
1 Dismantling and assembling gears
and shafts
Dismantling and assembling gears and shafts is not intended for
the time being.
96 Rep. gr.35 - Gears, shafts

39 – Final drive - differential

1 Oil seals
⇒ “1.1 Overview of fitting locations - seals”, page 97
⇒ “1.2 Renewing left seal”, page 97
1.1 Overview of fitting locations - seals
1 - Gearbox
2 - Seal
❑ For input shaft
3 - Seal, right
4 - Seal
❑ For selector shaft
5 - Left seal
1.2 Renewing left seal
Note
The seal on the right side is renewed in the same way.
1. Oil seals 97
♦ Tapered roller bearing puller - T10055-
♦ Electric drill, commercially available

♦ Metal drill bit, 2 to 4 mm in diameter, commercially available
♦ Sealing grease - G 052 128 A1-
• Gearbox is installed.
– Remove left drive shaft ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Drive shafts; Removing and installing drive shafts .
– Grease drill bit -3- so that metal chips adhere to it.
Caution
Risk of damage to bearing behind the seal.

♦ Drill a hole only into the sheet-metal ring of the seal.
♦ Do not screw in the self-tapping screw too far.
– Seal drive shaft aperture on gearbox with a clean cloth -2-.

– Using the 2 … 4 mm drill bit, carefully drill a hole into outer
sheet metal ring -1- of oil seal.
98 Rep. gr.39 - Final drive - differential

– Screw a self-tapping screw, approx. 4 mm in diameter, into

hole drilled into oil seal.
– Pull out seal using puller - T10055- and adapter - T10055/2- .
Caution

♦ Make sure no metal chips get into gearbox and into open‐
ing for drive shaft. Vacuum out metal chips first if neces‐
sary.
– Carefully remove cloths. When doing this, make sure that no

metal chips get into gearbox.
– Carefully clean gearbox and opening for drive shaft.
Note
If only the sheet metal ring could be pulled out, carefully lever out
rest of seal with a screwdriver.
• Installation position: open side of seal faces towards gearbox
– Fit seal by hand in a straight line, and push it in as far as pos‐
sible so that it is firmly seated in gearbox housing.
– Drive in seal to stop with thrust piece - T10457- , being careful

not to cant seal.
Torque settings
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Lower sus‐
pension link, swivel joint; Assembly overview - lower suspen‐
sion link, swivel joint .
1. Oil seals 99

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Service

Service Department. Technical Information

7.2 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

1.1 Safety precautions when working on ve‐

1.1.1 General safety precautions when work‐

In the event of uncertainties regarding the terms “high-voltage

Danger to life due to high voltage

Risk of injury due to unexpected motor start

Handling high-voltage cables

1.1.2 Safety precautions for work on a high-

2 Rep. gr.00 - Technical data

1.1.3 Safety precautions when re-energising

1.1.4 Safety precautions when working in the

Hazardous voltage in the event of damaged high-voltage com‐

4 Rep. gr.00 - Technical data

1.1.5 Safety precautions for work on a high-

Risk of injury due to unexpected motor/engine start and risk of

1.1.6 Safety precautions for work on a high-

Risk of injury due to unexpected motor start

1.2 General safety provisions

Risk of injury and accident by accidental engagement of gear

To prevent personal injury and damage to or destruction of elec‐

Risk of irreparable damage to electronic components when

– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

1.3 Safety measures when working on ve‐

Injury hazard as a result of automatic engine start in vehicles

1.4 Safety precautions when using testers

Risk of accident due to distraction and inadequate securing of

6 Rep. gr.00 - Technical data

1.5 Safety precautions when tow-starting or

If the vehicle has to be towed, the selector lever must be in the

It is not possible to tow-start the engine, e.g. if the battery is too

2.1 Gearbox identification

Volkswagen Technical Site: http://vwts.ru http://vwts.info

The gearbox code is also indicated on the vehicle data stickers.

8 Rep. gr.00 - Technical data

3.1 General information

Risk of damage to gearbox.

Gear oil filter change - »Yes or no?«

The gear oil filter does not have to be changed as a matter of

Do not change the filter if:

Gear change point variations for gradients

3.2 Rules for cleanliness

3.3 General repair instructions

10 Rep. gr.00 - Technical data

3.4 Safety functions of gearbox control unit

The failures detected by the gearbox may cause 4 different states.

12 Rep. gr.00 - Technical data

4.1 Allocation gearbox - engine

4.1.1 Golf 2013 ►, Golf 2017 ►

4.1.2 Passat 2015 ►, Passat Estate 2015 ►

Risk of damage to gearbox.

– Check gear oil level ⇒ page 61 .

Volkswagen Technical Site: http://vwts.ru http://vwts.info

1.1 Assembly overview - dual clutch

1.2 Renewing input shaft seal

♦ Thrust piece - T40403- with sleeve

14 Rep. gr.30 - Clutch