8 Speed Automatic Gearbox 09p Eng

Service
Workshop Manual
Arteon 2018 ➤
8-speed automatic gearbox 09P
Edition 04.2018
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
32 - Torque converter
37 - Controls, housing
38 - Gears, control
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.
Arteon 2018 ➤
8-speed automatic gearbox 09P - Edition 04.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 General safety provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Notes on tow-starting/towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Identification of torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.3 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1 Allocation gearbox - engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.1 Overview of fitting locations - electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
32 - Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1 Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Assembly overview - torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Removing and installing torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3 Draining torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4 Removing and installing torque converter oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
37 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1 ATF circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1 Assembly overview - ATF circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 Removing and installing ATF cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2 ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1 Checking ATF level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2 Draining and filling ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3 Bleeding ATF system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2 Install gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.3 Specified torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6 Installing to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7 Bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.1 Removing bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.2 Installing bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8.1 Assembly overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8.2 Emergency release from position P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.3 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.4 Moving push-button in the handle to installation position . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.5 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8.6 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8.7 Checking and adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Contents i
Arteon 2018 ➤
8.8 Removing and installing multifunction switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

8.9 Adjusting multifunction switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
8.10 Renewing oil seal for selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
38 - Gears, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1 ATF system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.1 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.2 Removing and installing ATF strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2 Valve body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.1 Assembly overview - valve body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.2 Removing and installing valve body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

1 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.1 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.2 Draining and filling gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2 Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.1 Overview of fitting locations - seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.2 Renewing left oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.3 Renewing right oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3 Components of bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.1 Assembly overview - components of bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.2 Renewing bevel box seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.3 Renewing needle bearing (polygon bearing) for stub shaft . . . . . . . . . . . . . . . . . . . . . . . . 97
4 Gearbox control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.1 Removing and installing gearbox control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
ii Contents
Arteon 2018 ➤
00 – Technical data
1 Safety information
(VRL011634; Edition 04.2018)
⇒ “1.1 General safety provisions”, page 1
⇒ “1.2 Notes on tow-starting/towing”, page 1
1.1 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 working on vehicle with engine running, move se‐
lector lever into position “P” and apply parking brake.
1.2 Notes on tow-starting/towing
Caution
Danger of irreparable damage to gearbox.

♦ If the vehicle has to be towed, move the selector lever to
the “N” position and neither drive the vehicle at a speed
greater than 50 km/h nor a distance exceeding 50 km.
Note
It is not possible to tow-start the engine.
1. Safety information 1
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2 Identification
⇒ “2.1 Gearbox identification”, page 2
⇒ “2.2 Identification of torque converter”, page 2
2.1 Gearbox identification

Code letters and date -arrow- of gearbox manufacture -1-
Code letter -arrow 1-

Example:
“Automatic gearbox 09G” -arrow 2-
GGZ 08 05 02
I I I I
Codes Day Month Year of
production -2002-
The gearbox code also appears on the vehicle identification
plates.
2.2 Identification of torque converter

There are various types of torque converter. They are identified
by codes -arrow-.
For allocation torque converter/gearbox refer to ⇒ Electronic
Parts Catalogue (ETKA) .
2 Rep. gr.00 - Technical data

Arteon 2018 ➤
3 Repair instructions
⇒ “3.1 General repair instructions”, page 3
⇒ “3.2 Gaskets and seals”, page 4
⇒ “3.3 Nuts and bolts”, page 4
3.1 General repair instructions

To ensure flawless and successful gearbox repairs, the greatest
care and cleanliness as well as the use of good and proper tools
are essential. Obviously, the basic rules for safety also apply dur‐
ing repair work.
A number of general notes on the individual repair procedures,
which can otherwise be found in the relevant sections of the man‐
ual, are summarised here. They apply for this particular workshop
manual.
Tools
A summary of the special tools and workshop equipment used in
the workshop manual precedes each repair procedure and can
be found in “Special tools/Workshop equipment” binder.
Uncertainty often occurs with smaller bolts having low tightening
forces. Torque wrench 2…10 Nm - V.A.G 1783- can be used with
these bolts.
Gearbox
♦ If oil pan has been removed from gearbox or gearbox has no
fluid, do not run engine or tow vehicle.
♦ First thoroughly clean connecting points and surrounding
areas and then loosen bolts.
♦ When installing the gearbox, ensure that dowel sleeves be‐
tween the engine and gearbox are correctly located.
♦ Place removed parts on a clean surface and cover them to
prevent them from getting dirty. Use sheeting and paper for
this purpose. Use only lint-free cloths.
♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing.
♦ If repair work cannot be performed immediately, carefully cov‐
er or seal components.
♦ With gearbox removed, secure torque converter against falling
out.
♦ After installation, check the ATF level and top up
⇒ page 19 .
♦ Capacities ⇒ page 5 .
Guided Fault Finding, vehicle self-diagnosis and test instruments

Before making repairs to the automatic gearbox, determine the
cause of the fault as precisely as possible with the aid of “Guided
Fault Finding”.
Guided Fault Finding is carried out using ⇒ Vehicle diagnostic
tester e.g. vehicle diagnosis, testing and information system -
VAS 5051B- .
3. Repair instructions 3
Arteon 2018 ➤
3.2 Gaskets and seals

O-rings, seals, gaskets, oil seals and oil
♦ Always renew O-rings, seals and gaskets.
♦ After removing seals and gaskets, always inspect contact sur‐
face of housing or shaft for burrs or damage caused by re‐
moval.
♦ Coat O-rings with ATF to prevent pinching of rings during as‐
sembly.
♦ Only ever use ATF. Other types of lubrication cause faults to
occur in the gearbox hydraulics.
♦ Apply a thin layer of ATF to seals around outer circumference
and sealing lip -arrow- before installing.
♦ Open side of oil seal faces oil.
3.3 Nuts and bolts

♦ Loosen and tighten securing bolts and securing nut for covers
and housings diagonally.
♦ Torque settings are specified for unoiled nuts and bolts.
♦ 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- .
♦ Threaded holes into which self-locking bolts or bolts with lock‐
ing agent have been screwed must be cleaned (e.g. with a
screw tap). Otherwise there is a danger of the bolts shearing
off when refitted.
♦ Always renew self-locking bolts and nuts.

Arteon 2018 ➤
4 Technical data
⇒ “4.1 Allocation gearbox - engine”, page 5
⇒ “4.2 Capacities”, page 5
4.1 Allocation gearbox - engine
4.1.1 Identification codes, assembly alloca‐

tion - vehicles with front-wheel drive
If spare parts are required for a repair, refer to the gearbox code.
Automatic gearbox 09P front-wheel drive
Codes SCF
Engine 2.0 l - 200 kW TSI
4.1.2 Identification codes, assembly alloca‐

tion - Cars with all-wheel drive
If spare parts are required for a repair, refer to the gearbox code.
Automatic gearbox 09P, all-wheel drive
Codes SCG
Engine 2.0 l - 200 kW TSI
4.2 Capacities
4.2.1 8-speed automatic gearbox 09P, front-wheel drive

Capacities Planetary gearbox and final drive
Initial filling approx. 7.0 l
Lubricant ATF is available as a part. Part numbers can be found
in the ⇒ Electronic parts catalogue ETKA .
4.2.2 8-speed automatic gearbox 09P, all-wheel drive

Capacities Planetary gearbox and final drive Front bevel box
Initial filling approx. 7.0 l approx. 0.9 l
Lubricant ATF is available as a part. Part The final drive oil is available as a
numbers can be found in the ⇒ part. Part numbers can be found in
Electronic parts catalogue “ETKA”. the ⇒ Electronic parts catalogue
“ETKA”.
Volkswagen Technical Site: http://vwts.ru http://vwts.info
4. Technical data 5
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5 Electrical components
5.1 Overview of fitting locations - electrical

components
– Before working on electrical components, electrostatically dis‐
charge yourself (touch something that is earthed). Do not
touch connectors or electronic components directly.
1 - Valve body
❑ Fitting location
⇒ page 7
❑ Removing and installing
⇒ page 67
2 - Automatic gearbox control
unit - J217-
❑ The control unit trans‐
mits data to and re‐
ceives data from the da‐
ta bus
❑ Location and removing
and installing
⇒ page 101
3 - Engine control unit
❑ The control unit trans‐
mits data to and re‐
ceives data from the da‐
ta bus
❑ Installation location, re‐
moving and installing ⇒
Rep. gr. 24 ; Engine
control unit; Removing
and installing engine
control unit - J623-
4 - Multifunction switch - F125-
❑ Fitting location
⇒ page 7
⇒ page 57
❑ Adjusting ⇒ page 59
5 - Wiring harness for senders
and solenoid valves
❑ With gearbox oil tem‐
perature sender - G93-
❑ Fitting location ⇒ page 7
❑ Removing and installing ⇒ page 70
6 - Gearbox oil temperature sender - G93-
7 - Gearbox output speed sender - G195-
8 - Gearbox input speed sender - G182-

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9 - Selector mechanism
❑ With Tiptronic switch - F189-
❑ The Tiptronic switch - F189- is part of the selector mechanism
❑ Renew if selector mechanism is defective ⇒ page 52
10 - Selector lever position indicator - Y6-
❑ Removing and installing ⇒ Electrical system; Rep. gr. 90 ; Dash panel insert; Assembly overview - dash
panel insert
11 - Diagnostic connection
Multifunction switch - F125-

Location: multifunction switch is located on top of the gearbox.
Valve body
Location: valve body is bolted to underside of gearbox housing
and covered by pan.
Wiring harness for senders and solenoid valves

♦ With integrated gearbox oil temperature sender - G93-
-arrow-.
Location: Wiring harness is attached to valve body in gearbox.
5. Electrical components 7
Arteon 2018 ➤
Gearbox input speed sender - G182- and gearbox output speed

sender - G195-
Location: senders are installed in gearbox housing behind valve
body.
Diagnostic connection
Location: diagnosis connector -arrow- is located on left below
driver storage compartment.

Arteon 2018 ➤
32 – Torque converter
1 Torque converter
⇒ “1.1 Assembly overview - torque converter”, page 9
⇒ “1.2 Removing and installing torque converter”, page 10
⇒ “1.3 Draining torque converter”, page 11
⇒ “1.4 Removing and installing torque converter oil seal”,
page 11
1.1 Assembly overview - torque converter
Note
Illustration of torque converter and gearbox may differ from actual components.
1 - Torque converter
❑ Take measures to pre‐
vent it falling out when
gearbox is removed or
during transportation
⇒ page 10
❑ For code see ⇒ Elec‐
tronic parts catalogue
(ETKA)
❑ Identification ⇒ page 2
❑ Installing ⇒ page 10
2 - Seal
❑ For torque converter
❑ Renewing ⇒ page 11
1. Torque converter 9
Arteon 2018 ➤
Securing torque converter to prevent it from falling out

– To prevent it from falling out, secure torque converter for trans‐
portation using wire -A-, for example.
An unsecured torque converter may slide out when the gearbox
is tipped.
1.2 Removing and installing torque convert‐

er
Removing
– Remove gearbox ⇒ page 23 .
Note
Lay a cloth under the torque converter to catch ATF which may
run out.
– Pull torque converter forwards from gearbox and lay it on a

soft surface with opening upwards.
Installing
– Carefully push on torque converter hub via oil seal to first stop.
– While applying light pressure, turn torque converter towards
gearbox. The torque converter will slide noticeably further in‐
wards.
The torque converter is properly installed if it can be turned easily
by hand and sits around the whole circumference at an equal
depth in the gearbox.
Caution
If engine and gearbox are brought together with force because

the torque converter is improperly fitted, both gearbox and tor‐
que converter will be damaged.
During subsequent installation, observe the following in particu‐

lar.
10 Rep. gr.32 - Torque converter

Arteon 2018 ➤
Caution
Before and when tightening bolts on engine/gearbox flange,

check repeatedly that the torque converter can still be turned
behind the drive plate. If the torque converter cannot be turned,
it can be assumed that it is not properly installed and that the
follower of the torque converter or the ATF pump will be de‐
stroyed during the final tightening of the screw connections.
– Install gearbox ⇒ page 28 .
1.3 Draining torque converter

Special tools and workshop equipment required
♦ Used oil collector and extractor - V.A.G 1782-
If ATF is contaminated, drain torque converter as follows:

– Extract ATF from torque converter using used oil collection
and extraction unit - V.A.G 1782- and oil extraction probe.
1.4 Removing and installing torque convert‐

er oil seal
♦ Press tool - T10175-
1. Torque converter 11
Arteon 2018 ➤
♦ Removal tool - VW 681-
Removing
– Lever out torque converter oil seal using oil seal extractor lever
- VW 681- .
Installing
– Apply ATF to circumference and sealing lips of new oil seal.
• Installation position: open side of oil seal faces gearbox.
– Insert torque converter seal using thrust piece - T10175- until
it is flush.
12 Rep. gr.32 - Torque converter

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37 – Controls, housing
1 ATF circuit
⇒ “1.1 Assembly overview - ATF circuit”, page 13
⇒ “1.2 Removing and installing ATF cooler”, page 13
1.1 Assembly overview - ATF circuit
1 - Gearbox
2 - O-rings
❑ Renew after removal
3 - ATF cooler
⇒ page 13
4 - Bolt
❑ Qty. 4, M8 x 25
❑ 20 Nm
1.2 Removing and installing ATF cooler
1.2.1 Removing and installing ATF cooler

1. ATF circuit 13
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♦ Hose clamps - 3094-
♦ Engine bung set - VAS 6122-
♦ Pliers for spring-type clips

Removing
– Move selector lever to position »P«.
– Remove air filter housing ⇒ Rep. gr. 24 ; Air filter; Removing
and installing air filter housing .
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery tray .
– Detach selector lever cable from fastener -arrow-.
Note
♦ Mark coolant hoses to ATF cooler to prevent interchanging

during installation.
♦ On a warm engine, the cooling system is under high pressure.
♦ Before pulling off the coolant hoses, cover the cap on the
coolant expansion tank with a cloth and open carefully.
14 Rep. gr.37 - Controls, housing

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– Clamp off coolant hoses using hose clamps up to 25 mm -

3094- and disconnect them from ATF cooler.
– Seal coolant hoses and connection unions using suitable
bungs/plugs from engine bung set - VAS 6122- .
– Unscrew bolts -arrows-, and remove ATF cooler.

Installing
Install in the reverse order of removal, observing the following.
Note
Always renew O-rings.
– Connect coolant hoses to ATF cooler according to marks

made during removal.
– Check coolant level ⇒ Rep. gr. 19 ; Cooling system, coolant;
Draining and filling coolant .
– Install battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery tray .
– Check ATF level ⇒ page 16 .
– Install air filter housing ⇒ Rep. gr. 24 ; Air filter; Removing
Specified torques
♦ ⇒ “1.1 Assembly overview - ATF circuit”, page 13
1. ATF circuit 15
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2 ATF
⇒ “2.1 Checking ATF level”, page 16
⇒ “2.2 Draining and filling ATF”, page 19
2.1 Checking ATF level

♦ Adapter for oil filling - VAS 6262 A-
♦ Adapter - VAS 6262/2-
Please follow instructions:

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♦ If ATF must be added, use only ATF 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 17 .
Shorten breather pipe of adapter for oil filling - VAS 6262 A- as

follows:
– In order to ensure that the breather pipe of the adapter for oil
filling - VAS 6262 A- does not contact the bottom of some oil
bottles, the pipe must be shortened to 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- .
– Shorten breather pipe using pipe cutter - VAS 6056/2- , for

example.
Conditions
♦ Vehicle level, all mountings of lifting platform evenly at same
height
♦ Noise insulation removed
♦ ⇒ Vehicle diagnostic tester is connected.
♦ At start of work, oil temperature must not be above 45°C.
♦ Test temperature: 35 … 45°C
Checking
– Connect ⇒ Vehicle diagnostic tester and identify vehicle using
Guided functions .
– Select Check ATF level .
Note
If the oil temperature is above 45°C, allow the gearbox to cool

down.
• Engine is idling with selector lever in position “P”.

– Position drip tray for workshop hoist or used oil collection and
extraction unit - V.A.G 1782- under gearbox in area of ATF
inspection plug.
2. ATF 17
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– Unscrew ATF inspection plug -arrow-.
– Renew oil seal -arrow- of bolt.
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.
The ATF present in the overflow pipe runs out.

– Let surplus oil flow out.
– When excess oil has run out (when it begins only to drip), in‐
stall plug with new seal.
– Top up oil if no oil flows out.
Caution
An oil level which is too low or too high will impair the function
of the gearbox.
Topping up

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– Screw adapter of adapter for filling oil - VAS 6262 A- hand-

tight into inspection hole.
– Shake oil bottle before opening.
– Screw oil filler adapter - VAS 6262 A- onto oil bottle, following
instructions ⇒ page 16 .
– Add 1 l of ATF.
– Pull off adapter for oil filling - VAS 6262- at plug-in connector
and check:
If ATF now flows out of hole in adapter:
ATF does not need topping up.
– Drain ATF until it drips.
– Fit ATF inspection plug with new oil seal and tighten. This
concludes the ATF check.
If no ATF drips out of inspection hole:
– If a further litre has to be added ⇒ page 18 .
Note
♦ If the ATF circuit was opened, it must be bled after at the end
of the test ⇒ page 22 .
♦ The ATF level must then be checked again ⇒ page 17 .
Specified torques
♦ ⇒ “2.1 Assembly overview - valve body”, page 65
2.2 Draining and filling ATF

♦ Adapter for oil filling - VAS 6262 A-
2. ATF 19
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♦ For some oil bottles adapter - VAS 6262/6- must be used as

well.
Conditions
♦ Engine switched off
♦ Vehicle level, all mountings of lifting platform evenly at same
height
♦ Noise insulation removed if previously fitted
♦ Selector lever at “P”
♦ ⇒ Vehicle diagnostic tester is connected.
♦ At start of work, oil temperature must not be above 45°C.
– If ATF must be added, use only ATF listed as a replacement
part in ⇒ Electronic parts catalogue (ETKA) .
WARNING
Risk of injury from hot gearbox oil.
– Connect ⇒ Vehicle diagnostic tester and identify vehicle using

Guided functions .
– Select Check ATF level .
Note
If the oil temperature is higher than 45°C, allow gearbox to cool

down.

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WARNING
Do not start engine if there is no oil in gearbox.
– Engine switched off - do not start engine!

• Used oil collection and extraction unit - V.A.G 1782- is posi‐
tioned under gearbox.
– Unscrew ATF inspection plug -arrow-.
– Remove overflow pipe -1- through inspection hole.

– Drain ATF.
– Install overflow pipe.
– Screw oil filler adapter - VAS 6262 A- onto oil bottle, following
instructions ⇒ page 16 .
2. ATF 21
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– Screw oil filler adapter - VAS 6262/2- into ATF inspection hole
hand-tight.
WARNING
Shake bottles thoroughly before opening to ensure that sedi‐

ment at the bottom of the bottle mixes well with the oil.
– Add 3 litres of ATF ⇒ Electronic parts catalogue (ETKA) .

– To change bottle, shut off tap or hold adapter for oil filling -
VAS 6262 A- higher than gearbox.
– Remove adapter - VAS 6262/2- from oil pan and tighten ATF
inspection plug by hand.
– Switch selector lever to “P” position.
– Start engine.
– With brake pressed, shift through all selector lever positions
“P, R, N, D, S” at idling speed, leaving each position engaged
for about 10 seconds.
– Finally, check ATF level ⇒ page 16 .
Specified torques
♦ ⇒ “2.1 Assembly overview - valve body”, page 65
2.3 Bleeding ATF system

– First, check and top up ATF level as described in ⇒ page 16 .
WARNING
Wear protective goggles.
– Carry out road test during which the ATF temperature reaches
at least 90°C so that the ATF system can bleed itself.
As air escapes from the ATF system, the ATF level in the gearbox
sinks. Therefore, the ATF level must be checked again after it has
cooled off.
– Let ATF cool to below 30°C.
– Check ATF level again ⇒ page 17 .

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3 Removing and installing gearbox

⇒ “3.1 Removing gearbox”, page 23
⇒ “3.2 Install gearbox”, page 28
⇒ “3.3 Specified torques for gearbox”, page 29
3.1 Removing gearbox

♦ Gearbox support - 3282-
♦ Pin - 3282/29-
♦ Engine and gearbox jack - VAS 6931-
3. Removing and installing gearbox 23

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♦ Engine bung set - VAS 6122-
♦ Insert tool 18mm - T10509- or -T10179-
♦ Socket - T10061-
Removing
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery .
– Lever off selector lever cable -1- from gearbox selector lever
-2- using e.g. an open-end wrench.
– Pull off connector -6- from multifunction switch - F125- and lay
electrical wiring on bracket aside.
– Unscrew bolts -5- from cable support bracket -4-. Do not re‐
move securing clip -3-.

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– Detach selector lever cable from fastener -arrow-.
Note
♦ Do not bend or kink gear selector cable.

♦ To ensure that the cable is not a hindrance when removing
and installing the gearbox, raise the cable to a suitable position
on the body and tie using e.g. cable ties.
Note
♦ On a warm engine, the cooling system is under high pressure.

♦ Before removing the coolant hoses on the gearbox, cover the
cap -arrow- on the coolant expansion tank with a cloth and
open carefully.
– Lay lint-free cloths on gear oil cooler and gearbox to catch

escaping coolant.
– Clamp off coolant hoses using hose clamps up to 25 mm -

3094- and disconnect them from ATF cooler.
– Seal coolant hoses and connection unions using suitable
bungs/plugs from engine bung set - VAS 6122- .
– Remove coolant valve for gearbox - N488- from gearbox ⇒ 4-
cyl. direct injection engine (1.8 l and 2.0 l, 4V, EA 888 gen III,
turbocharger, chain drive); Rep. gr. 19 ; Coolant pump/ther‐
mostat assembly; Assembly overview - electric coolant pump .
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
Removing and installing starter .
– Unscrew upper connecting bolts -arrows- securing gearbox to

engine using e.g. double hexagon flex head socket.
– Support engine and gearbox in installation position ⇒ Rep. gr.
10 ; Assembly mountings; Supporting engine in installation
position .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Removing and installing noise
insulation .
– Remove front left wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liner; Assembly overview
- front wheel housing liner .

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– Remove electrical connector from gearbox as follows. Push

locking mechanism -1- in direction of arrow, fold out bar -2-
and then pull off connector -3- from gearbox.
Remove subframe. ⇒ Rep. gr. 40 ; Subframe; Assembly over‐
view - subframe
– Detach left and right drive shafts from gearbox ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and
installing drive shaft .
– Secure both drive shafts on suspension strut with tensioning

belts - T10038- .
The surface protection of the shafts must not be damaged.
Vehicles with all-wheel drive
– Remove bevel box ⇒ page 36 .
Continued for all vehicles:
– Remove six converter nuts -arrow-.
– To do this, turn engine with counterhold - T10172A- 60° for

each nut in engine direction of rotation -arrow-.
Note
♦ If all 6 nuts are not removed from the torque converter, the
torque converter will be pulled out when the gearbox is re‐
moved from the engine!
♦ To loosen the nuts of the torque converter, counterhold with
wrench - T03003- on belt pulley/vibration damper.

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– Unscrew the 3 engine/gearbox connecting bolts

-right arrows-. Engine/gearbox connecting bolt -left arrow- re‐
mains in situ until gearbox is ready to be removed completely.
– Remove securing bolts -arrows- of left assembly mounting for

gearbox.
– Then lower engine/gearbox assembly to dimension -a- using

spindles of support bracket - 10 - 222 A- .
Dimension -a- = about 70 mm
The gearbox is separated from the engine in this position.
– Place gearbox support - 3282- -A- on engine and gearbox jack

- VAS 6931- -B-.
Install gearbox support - 3282- with mounting elements to gear‐
box as follows:
• Engine and gearbox jack with gearbox support must be placed
under gearbox -1- in such a way that spindle -left arrow- points
in direction of travel.
• Spindle -right arrow- points towards left in direction of travel.
• Supports -C- must be inserted in annular groove of oil pan.
• Pin -D- is engaged in recess on gearbox.
– Then screw pin - 3282/29- into rear hole on gearbox for se‐
curing bolt of pendulum support.
– Support gearbox by raising engine and gearbox support slight‐
ly with care.
– Remove last engine/gearbox connecting bolt.

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– Press gearbox off engine -3- while pressing torque converter

-1- against gearbox in -direction of arrow- using, for example,
a screwdriver -2-.
– Carefully lower gearbox, ensuring »clearance« to other com‐
ponents.
– After gearbox has been removed, secure torque converter to
prevent it from falling out ⇒ page 10
– Installing gearbox ⇒ page 28
3.2 Install gearbox

Install in the reverse order of removal, observing the following:
– Check whether dowel sleeves are pressed into engine flange.
– Check seat of plate between engine and gearbox. The plate
must make contact with the engine around the whole circum‐
ference when it is pressed gently with both hands against the
engine. If the top does not contact the engine, it is not properly
engaged in the engine block.
– Check that torque converter is installed correctly ⇒ page 10 .
Further installation is carried out in the reverse order of removal.
– Align engine and gearbox in installation position. To do this,
lift until gearbox is fully in contact with engine/gearbox mount‐
ing.
Renew all bolts on assembly mounting.

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– Screw in new bolts -arrows- by hand first.

– Gearbox can be aligned using a screwdriver when tightening
bolts -arrows-.
Vehicles with all-wheel drive
– Install bevel box ⇒ page 43 .
Continued for all vehicles:
– Attach drive shaft to gearbox ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Re‐
moving and installing starter
– Install selector lever cable on gearbox and adjust
⇒ page 52 .
– Install battery tray and battery ⇒ Electrical system; Rep. gr.
27 ; Battery .
– Check ATF level ⇒ page 16 .
– Install front wheel housing liner ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Wheel housing liner; Assembly overview
- front wheel housing liner .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Removing and installing noise insu‐
lation .
– Carry out basic setting. To do this, connect ⇒ Vehicle diag‐
nostic tester and then choose Guided functions to “Perform
basic setting”.
Specified torques:
♦ Gearbox to engine ⇒ page 29
♦ Assembly mounting to gearbox ⇒ page 31
3.3 Specified torques for gearbox

⇒ “3.3.1 Gearbox carrier to engine and bevel box”, page 30
Item Bolt Nm
1, 2 M12×45 80
• With insert tool
T10179 or
T10509:
»65 Nm«
3 M12x65 with nut 80

4 M12×45 80
5, 6, 7, 8 M10×45 40
91) M12×70 80
A 2) Dowel sleeves for centring
• 1) Not applicable to 2.0 l engine
• 2) Dowel sleeves at positions 3 and 8 for 2.0 l engine.
Volkswagen Technical Site: http://vwts.ru http://vwts.info

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Component Nm
Assembly mountings to gearbox (renew bolts after 60 Nm + turn 90° further
each removal)
Earth strap to assembly mounting 25
Drive plate to torque converter 57
Heat shield for right drive shaft to bevel box 20
Propshaft to bevel box ⇒ Rep. gr. 39 ; Propshaft; Assembly overview - prop‐
shaft
Bevel box to gearbox 40 Nm + 90° further

♦ Renew bolts after re‐
moving.
3.3.1 Gearbox carrier to engine and bevel box

Installation location and tightening sequence:
Item Bolt
1 M10 x 21
2 M10 x 45
Sequence Bolts Specified torque

1. -1- and -2- Screw in to contact by hand
2. Tighten -2- 40 Nm
3. Tighten -1- 40 Nm
Heat shield for propshaft

♦ Bolt -A-: 20 Nm
♦ Bolt -B-: 40 Nm

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4 Assembly mountings
⇒ “4.1 Assembly overview - assembly mountings”, page 31
4.1 Assembly overview - assembly mountings
1 - Pendulum support
2 - Bolt
❑ Specified torque ⇒ Rep.
gr. 10 ; Assembly
mountings; Assembly
overview - assembly
mountings
3 - Bolt
gr. 10 ; Assembly
mountings; Assembly
overview - assembly
mountings
4 - Bolt
❑ 60 Nm +90°
5 - Bolt
❑ 50 Nm +90°
6 - Bolt
gr. 10 ; Assembly
mountings; Assembly
overview - assembly
mountings
7 - Gearbox mounting
❑ With support arm
⇒ Rep. gr. 10 ; Assem‐
bly mountings; Assembly overview - assembly mountings
8 - Engine support
❑ ⇒ Rep. gr. 10 ; Assembly mountings; Assembly overview - assembly mountings
9 - Bolt
❑ Specified torque ⇒ Rep. gr. 10 ; Assembly mountings; Assembly overview - assembly mountings
10 - Engine mounting
❑ With support arm
❑ Removing and installing ⇒ Rep. gr. 10 ; Assembly mountings; Assembly overview - assembly mountings
11 - Bolt
12 - Bolt
4. Assembly mountings 31
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13 - Bolt
14 - Bolt
Gearbox with threaded insert (e.g. “Heli-Coil”) for securing pen‐

dulum support.
Note
♦ There are threaded inserts, e.g. “Heli-Coil” in the bolting holes

for the pendulum support.
♦ Distinguishing feature: shoulder along beginning of thread
-arrow-.
♦ Note appropriate securing bolts and specified torque ⇒ Rep.
gr. 10 ; Assembly mountings; Assembly overview - assembly
mountings .

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5 Transporting gearbox
♦ Shackle - 10 - 222 A /12-
♦ Workshop hoist - VAS 6100-
Shackle - 3282- can be used both to transport automatic gearbox

and to set up gearbox support - 10 - 222 A /12- .
– Use wire -A-, for example, to prevent torque converter from
falling out during transportation.
– Secure shackle - 10 - 222 A /12- to top of gearbox housing.
– Engage hook of workshop hoist -VAS 6100- in shackle as
shown in diagram.
– Support gearbox using workshop crane - VAS 6100- and
shackle - 10 - 222 A /12- .
5. Transporting gearbox 33
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6 Installing to engine and gearbox sup‐

port
♦ Support clamp - VW 313-
♦ Engine and gearbox support - VW 540-
♦ Engine and gearbox support - VAS 6095-
Keep in mind that there is oil in the gearbox. Do not turn gearbox
with breathers downwards during transport or while on repair
stand. Oil will run out.
Note
If necessary, pull off breather cap and close using suitable plugs
to achieve an oil-tight seal.

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– Secure gearbox on engine and gearbox support - VW 540-

-arrows-.
– Use workshop hoist - VAS 6100- in support clamp - VW 313-
or engine and gearbox support - VAS 6095- .
WARNING
Centre of gravity of gearbox is located outside axis of rotation

on support clamp. To turn the gearbox on the support clamp -
VW 313- , the gearbox must be held by a 2nd mechanic to
prevent a complete turnover.
6. Installing to engine and gearbox support 35

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7 Bevel box
7.1 Removing bevel box

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Special tools and workshop

equipment required
7. Bevel box 37
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♦ Multipurpose tool - VW 771-

♦ Hexagon key extension, 8 mm - 3247-
♦ Supplementary set for engine and gearbox support - VW 540/1
B-
♦ Puller - T 10472-
♦ Counterhold tool - T10172A-
♦ Engine support - T10533-
– Raise vehicle. All 4 supports of lifting platform must be at same
height.
– Turn steering to straight-ahead position.
Note
After loosening centre bolt, do not lower vehicle to ground again.
– Depress brake pedal and loosen bolt of right drive shaft

-arrow- (2nd mechanic needed) ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40 ; Drive shaft; Removing and installing drive
shaft .
Note
So that the propshaft can be turned later in order to loosen it:
– Move selector lever to »N« position.

– Remove engine cover panel.
– Remove noise insulation below engine and gearbox. ⇒ Gen‐
eral body repairs, exterior; Rep. gr. 66 ; Noise insulation;
Removing and installing noise insulation .
– Remove connecting hose between charge air cooler and

charge air pipe ⇒ Rep. gr. 21 ; Charge air system; Assembly
overview - charge air system .
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .

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– Disconnect connector -1- from oil level and oil temperature

sender - G266- .
– Remove drive shaft heat shield -1-, if present, from bevel box
(-arrows-) ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive
shaft .
Caution
Risk of damage to flexible joint.

♦ Observe ⇒ Rep. gr. 26 ; Emission control; Assembly
overview - emission control .
– Remove front exhaust system from engine, raise it and tie it in

place ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Assembly
overview - silencer .
If fitted, remove heat shield for propshaft.
– Unscrew bolts -A- and -B- from bevel box, and remove heat
shield -1-.
– Mark position of propshaft with flexible coupling relative to

output shaft of bevel box -arrows-.
7. Bevel box 39
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– Unbolt propshaft -arrows- and pull off bevel box.
– Counterhold at rear final drive when loosening or tightening

propshaft.
Note
To loosen »next« bolt, turn propshaft further by turning rear

wheels at same time.
– Unscrew pendulum support bolts -1- from gearbox.

– Place a cloth on subframe to avoid damaging paint of prop‐
shaft when it is placed on subframe.
– Push font propshaft back to stop. Make sure not to damage

seal -arrow- in centring bush.
– Place front propshaft on heat shield or on subframe as appro‐
priate.

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– Set up engine support - T10533- as shown in figure and tighten

bolts hand-tight.
• -A- thin end
• -B- thick end
Bolt -3- = original pendulum support bolt
– Screw an M 8 x 30 mm bolt -1- with a washer -2- into threaded
hole for noise insulation.
It may be necessary to push the gearbox forwards slightly in order
to attach the engine support - T10533- .
– Force engine/gearbox as far forwards as possible by turning
spindle of engine support - T10533- . Avoid collisions between
components and radiator cowl.
– Unbolt gearbox carrier for bevel box.
Diesel engine:
– Unscrew bolts -A and B-, and remove gearbox carrier -1- for
bevel box.
Petrol engine:
– Unscrew bolts -1- and -2-, and remove carrier from bevel box.
Continuation for all:
– Unbolt bevel box at top from gearbox -arrows-.
7. Bevel box 41
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– Loosen lower securing bolts securing bevel box to gearbox

and unscrew only as far as dimension -a-.
Dimension -a- = 15 mm
This prevents the bevel box from falling down immediately when
loosened using multi-purpose tool - VW 771- .
– Fit puller - T 10472- to bevel box.
– Prepare multi-purpose tool - VW 771- with a washer -a- and 2

sleeves from the supplementary set for engine and gearbox
support - VW 540/1 B- as shown in the illustration.
– Bolt multi-purpose tool - VW 771- onto puller - T10472- and

loosen bevel box from gearbox.
– Remove multi-purpose tool - VW 771- and puller - T10472-
from bevel box.

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– Unscrew lower securing bolts -arrows- and remove bevel box.
7.2 Installing bevel box

– Grease splines of differential with grease for clutch plate
splines - G 000 100- .
– Install new retaining ring -arrow A- and new O-ring -arrow B-
on right stub shaft.
– Insert bevel box and press against gearbox as far as it will go.
Note
Turn stub shaft if spline position is unfavourable (bevel box cannot

be pressed to stop against gearbox).
– If splines are correctly positioned and shafts are centred, then

bevel box will slide to stop against gearbox.
Caution
To ensure that the retaining ring of the stub shaft engages

properly in the differential bevel gear, strike the face of the
spline stub with a plastic hammer. Do not pull bevel box force‐
fully against gearbox by turning securing bolts. Damage to
gearbox or bevel box could result.
– Screw on bevel box with new bolts -arrows- until finger-tight,

then tighten. Specified torque: ⇒ page 29 .
– Unbolt gearbox carrier for bevel box. Observe installation lo‐
cation and tightening sequence of bolts ⇒ page 30 .
7. Bevel box 43
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– If present, install drive shaft heat shield -1- on bevel box

(-arrows-) ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive
shaft; Removing and installing drive shaft heat shield .
– Fit propshaft on bevel box.
Note
When removing and installing the bevel box, do not damage the
seal in the propshaft flange -arrow-. Renew propshaft if damaged.
– Join bevel box and propshaft by turning spindle of engine sup‐

port - T10533- . Take note of seal in propshaft flange when
doing this.
– Remove engine support - T10533- .
– Bolt propshaft to bevel box -arrows- ⇒ Rep. gr. 39 ; Propshaft;

Removing and installing propshaft .

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– If present, install heat shield for propshaft.
– Secure pendulum support to gearbox using new bolts -1-.

Specified torque: ⇒ Rep. gr. 10 ; Assembly mountings; As‐
sembly overview - assembly mountings .
– Install right drive shaft ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Drive shaft; Removing and installing drive shaft .
– Install sections of exhaust system ⇒ Rep. gr. 26 ; Exhaust
pipes/silencers; Assembly overview - silencer .
Further installation is carried out in the reverse order of removal.
– Check gear oil in bevel box ⇒ page 72 .
– Following installation, check oil level in gearbox ⇒ page 16 .
gr. 66 ; Noise insulation .
Specified torques: ⇒ page 30
7. Bevel box 45
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8 Selector mechanism
⇒ “8.1 Assembly overview - selector mechanism”, page 46
⇒ “8.2 Emergency release from position P”, page 48
⇒ “8.3 Removing and installing selector lever handle”,
page 48
⇒ “8.4 Moving push-button in the handle to installation position”,
page 50
⇒ “8.5 Removing and installing selector mechanism”, page 52
⇒ “8.6 Checking selector mechanism”, page 54
⇒ “8.7 Checking and adjusting selector lever cable”, page 55
⇒ “8.8 Removing and installing multifunction switch”, page 57
⇒ “8.9 Adjusting multifunction switch”, page 59
⇒ “8.10 Renewing oil seal for selector shaft”, page 60
8.1 Assembly overview - selector mechanism
WARNING
Before working on vehicle with engine running, move selector

lever into position “P” and apply handbrake.

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1 - Handle with selector cover

❑ Do not remove handle
without reason. Only un‐
clip cover for emergen‐
cy release ⇒ page 48 .
⇒ page 48
2 - 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 52
❑ Checking and adjusting
⇒ page 55
3 - Bolt
❑ Secures selector mech‐
anism to selector hous‐
ing
❑ Qty. 4
❑ 4 Nm
4 - Plugs
5 - Hexagon flange nut
❑ Qty. 4
❑ M6 - 8 Nm.
❑ M8 - 20 Nm.
6 - Selector housing
7 - Bracket
❑ For selector lever cable
❑ Secured to ATF cooler
8 - Gearbox
9 - Cable support bracket
❑ For selector lever cable
❑ With integrated grommet and spacer for supporting cable support bracket on gearbox
10 - Bolt
❑ Adjuster screw for selector lever cable
❑ 13 Nm
11 - Selector lever cable
12 - Securing clips
❑ Secures selector lever cable on cable support bracket
13 - Bolt
❑ 20 Nm
14 - Securing clips
8. Selector mechanism 47
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8.2 Emergency release from position P

Do not remove handle
– Depress brake pedal or set handbrake.
– Open lid of storage compartment.
– Grasp under selector lever cover with one hand, and unclip
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«.
8.3 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”.

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Button -arrow- does not need to be pulled out by hand. Button

engages automatically in installation position when handle is
pulled off.
– Open lid of storage compartment.
– Grasp under selector lever cover with one hand, and unclip
cover by pulling it upwards.
– Separate electrical connector.
– Cut open clamp -arrow- under boot using side cutters.

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

possible to install the handle.
Installing
Install in reverse order of removal, observing the following:
• Selector lever is in position “D”.
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Note
♦ There is a chance that the button could be pressed into the

handle. Never install a handle with the button pressed in.
♦ Move button to installation position ⇒ page 50 .
♦ 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. Do not tighten

clamp yet.
– Press button after installation.
Note
If not installed correctly, the button remains inserted in the handle

after being pressed. If this happens, pull handle off again and
move push button to installation position again ⇒ page 50 . Then
fit the handle again.
– If the button returns to its start position when released, the

clamp can be tightened using the hose clip pliers - V.A.G
1275- .
– Connect electrical connector.
– Clip cover into position.
8.4 Moving push-button in the handle to in‐

stallation position

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♦ 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:
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– Carefully unclip handle trim -A- upwards.
– Using a screwdriver, for example, press small lever -1- for pull
rod into groove -2-. This action presses button -3- back into
installation position.
-I- button pressed in
-II- button in installation position
Note
♦ Press the lever only 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 button is
pressed.
8.5 Removing and installing selector mech‐

anism
Brief description
In the interior, the centre console must be removed.
The heat shield beneath the vehicle must be removed.
Removing
– Remove selector lever handle ⇒ page 48 .
– Remove centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; Centre console; Removing and installing centre con‐
sole .
– Remove centre console vent ⇒ Heating, air conditioning; Rep.
gr. 87 ; Air duct; Assembly overview - air routing and air dis‐
tribution in passenger compartment .
– Separate electrical connector from selector mechanism to ve‐
hicle wiring harness.

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Use pliers to remove securing clip -3- on cable support bracket
-4-. Do not use a sharp-edged lever. The selector lever cable
could otherwise be damaged. Bolts -5- are not unscrewed.
– Unhook selector lever cable from clip -arrow- on bracket.
Note
Securing clips for selector lever cable must always be renewed.
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.
– Raise vehicle.
– 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
Install in reverse order of removal. During this procedure, observe
the following:
Note
♦ Do not bend or kink gear selector cable.

♦ Do not grease selector lever cable.
♦ Following installation of selector mechanism, selector lever
cable must be checked for ease of movement and be adjusted.
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– Insert selector lever cable -1- into cable support bracket -4-
and install new securing clip -3-.
– Carefully push selector lever cable -1- onto gearbox selector
lever -2-.
If it has been removed, install cable support bracket -4- with bolts
-5- on gearbox.
– Attach selector lever cable to clip on retainer -arrow-.

– Install heat shield below selector mechanism ⇒ General body
repairs, exterior; Rep. gr. 66 ; Mouldings/trims/extensions;
Assembly overview - heat shield .
– Install centre console vent ⇒ Heating, air conditioning; Rep.
gr. 87 ; Air duct; Assembly overview - air routing and air dis‐
tribution in passenger compartment .
– Install centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; Centre console; Removing and installing centre con‐
sole .
– Install selector lever handle ⇒ page 48 .
– Adjust selector lever cable ⇒ page 55 .
– Check selector mechanism ⇒ page 54 .
Specified torques
♦ ⇒ “8.1 Assembly overview - selector mechanism”, page 46
8.6 Checking selector mechanism

The starter must not operate in the selector lever positions “R”,
“D”, “S” and in Tiptronic position.
On right-hand drive vehicles, the starter must operate in selector
lever positions “P” and “N” only when the push-button in the se‐
lector lever handle is not pressed.
Over 5 km/h
When the selector lever is shifted to “N”, the selector lever lock
solenoid must not lock the selector lever. Selector lever can be
shifted back into a driving range.
Under 5 km/h
When the selector lever is shifted to “N”, the selector lever lock
solenoid must lock the selector lever only after approx. 1 second.
Selector lever cannot be shifted out of “N” position until brake
pedal is depressed.
Selector lever in “P” position and ignition switched on
• Brake pedal not depressed:
Selector lever is locked and cannot be shifted out of “P” position
when the push-button is pressed. Solenoid for selector lever lock
blocks selector lever.

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Solenoid for selector lever lock releases selector lever. It is pos‐

sible to shift into a driving gear. Slowly shift selector lever from
“P” through to “S”, checking whether selector lever position in
dash panel insert corresponds to actual selector lever position.
Selector lever in “N” position and ignition switched on
Selector lever is locked and cannot be shifted out of “N” position
with the push-button pressed. Solenoid for selector lever lock
blocks selector lever.
• Brake pedal is depressed:
Solenoid for selector lever lock releases selector lever. It is pos‐
sible to shift into a driving gear.
Selector lever in position “Tiptronic”
• Shift selector lever into Tiptronic gate.
The illumination of the “D” symbol in the selector mechanism cov‐
er must go out. “+” and “-” symbols must light up.
When the selector lever is shifted into the Tiptronic gate, the se‐
lector lever position display in the dash panel insert must change
from “P R N D S” to “6 5 4 3 2 1”.
Ignition and light switched on
The respective symbol in the shift mechanism cover lights up.
Selector lever position indicator
Simultaneous illumination of all selector lever position display
segments indicates gearbox emergency running mode.
8.7 Checking and adjusting selector lever

cable
♦ Torque wrench - V.A.G 1331-
Brief description
To check ease of movement of selector lever cable, it must be
removed from the gearbox and the free end must be placed so
that it does not bump against anything.
Then move selector lever and reinstall the selector lever cable.
Then the selector lever cable must be adjusted ⇒ page 56 .
Do not grease connection of selector lever cable.
Checking
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– Loosen adjuster screw -arrow- of selector lever cable -1-.

– Move selector lever repeatedly from »P« to »S« and back to
»P«.
• The selector lever and selector lever cable must be free to
move.
– Install selector lever cable again.
– Then, adjust selector lever cable ⇒ page 56 .
The selector lever cable must always be adjusted whenever
♦ The selector lever cable has been removed from the gearbox.
♦ The engine and/or gearbox has been removed and installed.
♦ Parts of the assembly mounting have been removed and in‐
stalled.
♦ The cable itself or the selector mechanism has been removed
and installed.
♦ The position of the engine and gearbox is shifted, for example
to install it free of tension.
Adjusting:
Adjuster screw -arrow- must be »loosened«.

– Set gearbox selector lever -2- on gearbox to position “P” (push
gearbox selector lever towards rear).
WARNING
The parking lock must be engaged.
– To do this, turn both front wheels simultaneously »under the

car« in the same direction until the parking lock can be heard
to engage.
• The parking lock is engaged when both front wheels cannot
be turned in the same direction at the same time.
– Gently push knob of selector lever forwards and backwards
but under no circumstances must you shift out of “P”.
In this way the inner cable of the selector lever cable finds its
optimal position.
– Tighten bolt -arrow- .

This completes the adjustment.
Specified torque
♦ ⇒ Item 10 (page 47)

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8.8 Removing and installing multifunction

switch
Removing multifunction switch - F125-

– Move selector lever to position “N”.
– Switch off ignition.
– Pull off connector -6- from multifunction switch - F125- and lay
electrical wiring on bracket aside.
– Unscrew bolts -5- from cable support bracket -4-. Do not re‐
move securing clip -3-.
– Unscrew nut -1-.

– Pull spring lock washer -2- and gearbox selector lever -3- off
selector shaft -4-.
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– Carefully bend back hooks of lock washer -2- using a screw‐

driver.
– Renew securing clip if hooks have broken off.
– Unscrew nut -1-.
– Unscrew bolt -5-.
– Pull multifunction switch -4-, together with washers -2- and
-3-, off selector shaft -6-.
Installing multifunction switch - F125-
– Place multifunction switch -4- on selector shaft -6-.

– Tighten securing bolts -5- for multifunction switch hand-tight.
– Bend hooks of lock washer -2- back.
– Place washer -3- on selector shaft -6-.
– Install washer -2- with hooks pointing up.
– Install washer -2- with long, narrow guides in long, narrow re‐
cesses of selector shaft -6-.
– Tighten nut -1- to specified torque.
– Secure nut -1- by bending up hooks on lock washer -2-.
Note
♦ If one or more lock washer hooks break off due to bending,

renew washer.
♦ Before installing gearbox selector lever to selector shaft, ad‐
just multifunction switch - F125- ⇒ page 59 .

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– Fit gearbox selector lever -3- onto selector shaft -4-.

– Use gearbox selector lever -3- to set gearbox to position “P”.
To do this, push gearbox selector lever -3- opposite to direc‐
tion of travel to rear stop.
– Then, use gearbox selector lever -3- to shift gearbox to posi‐
tion “N”. To do this, push gearbox selector lever -3- two detent
positions forwards in direction of travel.
– Place spring ring -2- and nut -1- on selector shaft -4-.
– Tighten nut -1- to specified torque.
– Adjust selector lever cable ⇒ page 55 .
– Check selector mechanism ⇒ page 54 .
Specified torques
Component Nm
Multifunction switch - F125- to selector shaft 7
Gearbox selector lever to selector shaft 13
♦ ⇒ “8.1 Assembly overview - selector mechanism”, page 46
8.9 Adjusting multifunction switch

♦ Adjusting tool - T10173-
– Move selector lever to position “N”.

– Do not kink selector lever cable.
Adjustment prerequisites
• Selector lever cable has been removed from gearbox selector
lever
• Selector shaft is set to “N” position.
• Securing bolts for multifunction switch - F125- have been loos‐
ened.
• Gearbox selector lever has been removed from selector shaft
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– Fit setting gauge - T10173- on selector shaft -2-, and turn mul‐
tifunction switch -1- until setting gauge engages in lug on
connector of multifunction switch .
Note
If the lug of the connector cannot engage in the groove of the

setting gauge , the gearbox is no longer in position “N”. In this
case, use the setting gauge to shift the gearbox to position “N”.
– Using bolt -3-, secure setting gauge on selector shaft -2-.

– Tighten bolts -arrows- to specified torque.
– Remove setting gauge .
– Further installation is performed in the reverse order of re‐
moval ⇒ page 58 .
Specified torques
Component Nm
Multifunction switch - F125- to gearbox 6
8.10 Renewing oil seal for selector shaft

♦ Extractor hook - T20143/1-
– Remove multifunction switch - F125- ⇒ page 57 .

– Using extractor hook - T20143/1- , carefully lever out selector
shaft seal. Do not damage selector shaft.
– Apply ATF to circumference and sealing lips of oil seal.
• Installation position: open side of seal faces gearbox housing.

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– Drive in new seal onto stop with thrust piece - T10174- . Do

not cant oil seal in the process.
– Install multifunction switch - F125- ⇒ page 58 .
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38 – Gears, control
1 ATF system
⇒ “1.1 Removing and installing oil pan”, page 62
⇒ “1.2 Removing and installing ATF strainer”, page 63
1.1 Removing and installing oil pan

♦ Drip tray for workshop hoist - VAS 6208-
Removing oil pan

– Remove noise insulation below gearbox.
– Place drip tray or used oil collection and extraction unit - V.A.G
1782- underneath.
– Unscrew and remove ATF inspection plug -A-.
– Remove overflow pipe -C- and allow remaining ATF to drain.
62 Rep. gr.38 - Gears, control

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– Loosen oil pan bolts -arrows- in diagonal sequence and re‐

move.
Note
Some ATF always remains in the pan.
– Remove oil pan together with oil pan gasket.

Installing oil pan
– Clean two magnets in recesses of oil pan. Make sure that
magnets make full contact with oil pan.
– Check that seal is undamaged and all spacer sleeves (qty. 8)
are present.
Otherwise renew seal.
– Fit oil pan with seal, taking care not to pinch any wires.
– Ensure proper seating of oil pan seal.
– Tighten pan bolts -arrows- diagonally in several stages; torque

specification ⇒ page 65 .
– Screw in overflow pipe -C-; torque specification ⇒ page 65 .

– Insert seal -B- for ATF inspection plug -A-.
– Screw in ATF inspection plug -A- hand-tight with new seal
-B-.
– Fill with ATF; check ATF level and top up ⇒ page 19 .
gr. 66 ; Noise insulation; Assembly overview – noise insula‐
tion .
1.2 Removing and installing ATF strainer

Remove ATF strainer
– Remove oil pan ⇒ page 62 .
1. ATF system 63
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– Unscrew bolts -arrows- of ATF strainer.

– Pull ATF strainer -A- off valve body.
Install ATF strainer
– Thinly coat seals on intake neck of ATF strainer with ATF.
– The ATF strainer must be renewed if seals are loose or de‐
fective.
– Place ATF strainer -A- onto valve body and tighten bolts
-arrows-; torque specification ⇒ page 65 .
– Install oil pan ⇒ page 62 .

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2 Valve body
⇒ “2.1 Assembly overview - valve body”, page 65
⇒ “2.2 Removing and installing valve body”, page 67
WARNING
Do not run engine or tow vehicle with pan removed or when

there is no ATF in gearbox.
♦ The valve body and the wiring harnesses can also be removed
when the gearbox is installed.
♦ Insert O-rings with ATF. Other lubricants lead to malfunction‐
ing of the gearbox hydraulics.
♦ Always renew a valve body which is fouled or defective.
♦ Only use lint-free cloths.
♦ After oil pan has been installed, ATF level must be topped up
and checked ⇒ page 19
2.1 Assembly overview - valve body
1 - Gearbox housing
2 - O-ring
3 - Multifunction switch - F125-
⇒ page 57
❑ Adjusting ⇒ page 59
4 - Locking plate
5 - Nut
❑ 7 Nm
6 - Gear lever
❑ For selector shaft
❑ On outside of multifunc‐
tion switch
⇒ page 57
7 - Nut
❑ With spring lock washer
❑ 13 Nm
8 - Bolt
❑ Qty. 2
❑ 6 Nm
9 - Valve body
⇒ page 67
❑ Allocation ⇒ Electronic
parts catalogue (ETKA)
2. Valve body 65
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10 - Bolt
❑ For securing valve body
in gearbox
❑ Qty. 7, M6 × 27
❑ Always renew bolts
❑ 8 Nm + 90°
11 - Bolt
❑ For securing valve body in gearbox
❑ Qty. 7, M6 × 21
❑ Always renew bolts
❑ 8 Nm + 90°
12 - Gear lever
❑ On inside of valve body
13 - Locking plate
14 - Nut
❑ 10 Nm
15 - Oil strainer
16 - Bolt
❑ Qty. 3
❑ For securing strainer to valve body
❑ 11 Nm
17 - Seal
❑ With spacer sleeves (qty. 8)
❑ Examine before fitting
❑ Renew brittle, cracked or deformed seal
18 - Overflow pipe
❑ Unscrew to drain ATF
❑ 2 Nm
19 - Oil pan
20 - Seal
❑ Always renew
21 - ATF inspection plug
❑ 25 Nm
22 - Bolt
❑ Tighten oil pan bolts diagonally in several stages.
❑ 7 Nm
23 - Bolt
❑ 11 Nm
24 - Retaining plate
25 - Gearbox oil temperature sender - G93-
❑ Integrated into wiring harness
❑ Is removed together with wiring harness

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26 - Wiring harness for senders and solenoid valves

❑ With O-ring on plug, always renew O-ring
❑ With gearbox oil temperature sender - G93-
❑ Allocation ⇒ Electronic parts catalogue (ETKA)
27 - Bolt
❑ 6 Nm
28 - Bolt
❑ 7 Nm
30 - Bolt
❑ 6 Nm
32 - Selector shaft
2.2 Removing and installing valve body

⇒ “2.2.1 Removing and installing wiring harness for senders and
solenoid valves”, page 70
⇒ “2.2.2 Removing and installing gearbox input speed sender
G182 and gearbox output speed sender G195 ”, page 71
♦ Torque angle wrench - V.A.G 1756-
– With ignition switched off, disconnect battery earth strap ⇒

Electrical system; Rep. gr. 27 ; Battery; Disconnecting and
connecting battery .
2. Valve body 67
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– Remove ATF strainer ⇒ page 63 .
– Remove wiring harness from valve body ⇒ page 70
– If fitted, bend back securing tab on selector lever -arrows-.
– Remove selector lever -1- from selector shaft.

– In the process, carefully grip selector lever -1- with pliers -2-
so that torque is not transferred to multifunction switch - F125- .
– Note spool valve -3- on valve body into which selector lever
engages so that this is not damaged.
The spool valve is very »sensitive«. Even the slightest damage
will lead to faults in operation.
– Therefore, always push spool valve into valve body, secure
against falling out and never interchange.
The bolts securing the valve body to the gearbox housing are of
different lengths and must be replaced.
Only marked securing bolts -A- and -B- may be loosened.
Caution
If other bolts are loosened, the function of the valve body will
be impaired and/or the valve body will be distorted.
– Working diagonally, remove securing bolts -A- and -B- for

valve body and carefully remove valve body.
Installing:
Install in reverse order of removal, observing the following:
Wiring harness is attached to senders beneath valve body.
– Insert valve body and secure on gearbox with new bolts

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Lengths of bolts and location on valve body

Bolts -A- Qty. 7, M6 × 27
Bolts -B- Qty. 7, M6 × 21
– Tighten securing bolts -A- and -B- of valve body in diagonal
sequence. Specified torque ⇒ page 65
– Push selector lever -2- onto selector shaft -5-.

Ensure that selector lever pin -2- engages into spool valve -1-. If
necessary, reposition spool valve accordingly.
– Set lock washer -4- and nut -3- on selector shaft -5-.
Centring collar of nut must face washer and run into washer on
tightening.
– Tighten selector lever nut -1- to specified torque ⇒ page 65 .

– In the process, carefully grip selector lever -1- with pliers -2-
so that torque is not transferred to multifunction switch - F125- .
– Note spool valve -3- on valve body into which selector lever
engages so that this is not damaged.
– If securing tab is present, bend it up on nut -arrows-.

– Install wiring harness on valve body ⇒ page 70
– Install ATF strainer ⇒ page 63 .
2. Valve body 69
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2.2.1 Removing and installing wiring harness

for senders and solenoid valves
– Remove electrical connector from gearbox as follows. Push
locking mechanism -1- in direction of arrow, fold out bar -2-
and then pull off connector -3- from gearbox.
– Drain ATF ⇒ page 19 .
– Remove ATF strainer ⇒ page 63 .
Note
Before separating the electrical connectors, mark which solenoid

valves and senders belong to which connectors.
– Separate electrical connectors -B to K-. Pull off connector

-A- from retainer.
– Unscrew bolt -1- and remove together with retaining plate
-2-. Detach wiring harness on valve body -arrows-.
– Remove valve body ⇒ page 67 .
– Pull off connector from sender -arrows-.

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– Unscrew bolt for gearbox connector.

– Pull connector and wiring harness outwards out of gearbox
housing.
– Renew O-ring on connector.
– Push connector with new O-ring into gearbox as far as stop.
– Tighten gearbox bolt, tightening torque ⇒ page 65 .
– Install valve body ⇒ page 67 .
2.2.2 Removing and installing gearbox input

speed sender - G182- and gearbox out‐
put speed sender - G195-
– Remove valve body ⇒ page 67 .
– Unscrew bolt -1- from gearbox output speed sender - G195- .
– Unscrew bolt -2- from gearbox input speed sender - G182- .
– Pull sender out of gearbox housing.
– Push sender into gearbox housing as far as it will go.
– Tighten bolt -1- and -2-, tightening torque ⇒ page 65 .
– Install valve body ⇒ page 67 .
2. Valve body 71
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39 – Final drive - differential

1 Gear oil
⇒ “1.1 Checking gear oil level”, page 72
⇒ “1.2 Draining and filling gear oil”, page 73
1.1 Checking gear oil level

♦ Used oil collector and extractor - VAS 6622A-
Note
♦ The bevel box is bolted to side of the gearbox and has its own
oil supply.
♦ Specifications for gear oil ⇒ Electronic Parts Catalogue “ET‐
KA”
Requirement
• Bevel box must be in installation position.
height.
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
– Put used oil collection and extraction unit - VAS 6622A- un‐
derneath.
72 Rep. gr.39 - Final drive - differential

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– Unscrew oil filler plug -1-.

Renew oil filler plug after each removal.
Oil level is correct when bevel box is filled to lower edge of filler
hole.
Note
♦ Clean bevel box thoroughly to remove any remains of the

emerged oil.
♦ Disregard -item 2-.
– If necessary, top up gear oil ⇒ page 73 .

– Screw in new oil filler plug -1-.
– Tighten bolt to specified torque ⇒ page 75 .
1.2 Draining and filling gear oil
Note
♦ The gear oil in the bevel box must only be drained in the event
of repairs. The oil is not intended to be changed on a regular
basis.
♦ Specifications for gear oil ⇒ Electronic Parts Catalogue

♦ Used oil collector and extractor - VAS 6622A-
♦ Filling device - VAS 6291 A-
1. Gear oil 73
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♦ Not illustrated: Torque wrench - V.A.G 1331-

Requirement
• Vehicle is level.
height.
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
– If fitted, remove right drive shaft heat shield from bevel box
-arrows- ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive
shaft; Removing and installing drive shaft .
– Place used oil collection and extraction unit - VAS 6622- below
gearbox.
WARNING
Risk of injury from hot gear oil.

♦ Wear protective goggles.
♦ Wear acid-resistant gloves
– Unscrew oil drain plug -2-, and drain gear oil.

– Screw in new oil drain plug.
Note
To collect escaping gear oil, leave used oil collection and extrac‐
tion unit - VAS 6622- underneath.
– Unscrew oil filler plug -1-.

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– Screw adapter - VAS 6291/2- -A- in to stop.

– Engage elbow -B- in adapter -A-.
– Top up with oil.
Note
♦ If bevel box has been properly filled, oil runs out at adapter
-A-.
♦ Continue with filling procedure if no oil has run out yet.
– After bevel box has been properly filled, unscrew adapter -

VAS 6291/2- .
– Screw in »old« oil drain plug and tighten slightly.
– Start engine, engage gear and allow gearbox to turn for ap‐
prox. 2 minutes.
– Turn off engine and unscrew plug from oil filler hole.
– Check oil level, if necessary top up gear oil again to lower edge
of filler hole.
– Screw in new oil filler plug.
Note
Clean bevel box thoroughly to remove any remains of the

emerged oil.
– If present, install heat shield above right drive shaft ⇒ Running

gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and
installing drive shaft .
tion .
Specified torques:
1- Oil filler plug
• Renew after removal
• 15 Nm
2- Oil drain plug

• Renew after removal
• 15 Nm
1. Gear oil 75
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2 Seals
⇒ “2.1 Overview of fitting locations - seals”, page 76
⇒ “2.2 Renewing left oil seal”, page 77
⇒ “2.3 Renewing right oil seal”, page 78
2.1 Overview of fitting locations - seals
1 - Gearbox
2 - Seal, right
❑ Renew on vehicles with
front-wheel drive
⇒ page 78
❑ Renewing large oil seal
on right for all-wheel
drive vehicles
⇒ page 80
3 - Small seal on right
❑ Renew on vehicles with
all-wheel drive
⇒ page 80
4 - Seal
5 - Right stub shaft
❑ Vehicles with all-wheel
drive
6 - Needle bearing (polygon
bearing)
❑ Stiff when right stub
shaft is removed but not
a sign of fault
❑ Acoustic test only possi‐
ble when installed
❑ Check for damage, e.g.
cracking in outer race
7 - Seal
❑ For stub shaft on right of
bevel box
8 - Bevel box
9 - Seal
❑ For output flange
❑ To renew, remove bevel box ⇒ page 36
10 - Seal
❑ Between gearbox and bevel box, on left of bevel box
❑ Vehicles with all-wheel drive
11 - Seal
❑ For stub shaft on left of bevel box

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❑ Vehicles with all-wheel drive
12 - Seal, left
2.2 Renewing left oil seal

♦ Puller - T10055-
♦ Adapter - T10055/2-
♦ Electric drill, commercially available
♦ Metal drill bit, 2 to 4 mm in diameter, commercially available
♦ Sealing grease - G 052 128 A1-
Procedure
– 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 oil seal.

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

– Using a 2 … 4 mm drill bit, carefully drill a hole into outer sheet
metal ring -1- of oil seal.
2. Seals 77
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– Screw a self-tapping screw, approx. 4 mm in diameter, into

hole drilled in oil seal.
– Pull out oil seal using puller - T10055- and adapter -
T10055/2- .
Caution
Risk of damage to gearbox.

♦ 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.
– Apply gear oil to circumference and sealing lips of new oil seal.
• Installation position: open side of oil seal faces towards gear‐
box
– Fit oil seal by hand in a straight line, and push it in as far as
possible so that it is firmly seated in gearbox housing.
– Drive in oil seal to stop with thrust piece - T10176- , being

careful not to tilt oil seal.
– Check and top up ATF level ⇒ page 16 .
Specified torques
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Lower sus‐
pension link, swivel joint; Assembly overview - lower suspen‐
sion link, swivel joint .
2.3 Renewing right oil seal

⇒ “2.3.1 Renewing right oil seal - front-wheel drive vehicles”, page
78
⇒ “2.3.2 Renewing right oil seal - all-wheel drive vehicles”,
page 80
2.3.1 Renewing right oil seal - front-wheel

drive vehicles

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♦ Drip tray - V.A.G 1306-
♦ or drip tray for workshop hoist - VAS 6208-
Note
Seal can be renewed with gearbox installed.
Removing
– Raise vehicle.
Rep. gr. 66 ; Underbody panel; Removing and installing un‐
derbody panels .
– Remove right drive shaft. ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft
1782- underneath.
– Carefully lever out oil seal, ensuring that shaft in gearbox is
not damaged.
Installing oil seal:
Install in reverse order of removal. During this procedure, observe
the following:
2. Seals 79
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– Apply ATF to circumference and sealing lips of oil seal.

– Drive in seal to stop with thrust piece - T10105- , being careful
not to cant seal.
– Install drive shaft ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shaft; Removing and installing drive shafts .
gr. 66 ; Underbody panel; Removing and installing underbody
panels .
2.3.2 Renewing right oil seal - all-wheel drive

vehicles
♦ Seal puller - T10397-
♦ Seal puller - T10398-
♦ Assembly tool - T10399-

Removing small oil seal
– Lock oil seal extractor - T10397- using knurled screw and at‐
tach torque wrench.
– Turn oil seal extractor into oil seal -2-.

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– Unlock oil seal extractor using knurled screw and turn further.
– Pull out oil seal.
Note
If the seal slips off:
– Apply oil ring extractor again and pull out seal.

Removing large oil seal
– Lock oil seal extractor - T10398- using knurled screw and at‐
tach torque wrench.
– Turn oil seal extractor with 100 Nm torque into oil seal -1-.
– Unlock oil seal extractor using knurled screw and turn further.
Note
If the seal slips off:
– Turn oil seal extractor with 120 Nm torque into oil seal.
Installing small oil seal
– Insert assembly tool - T10399/1- .

– Place oil seal -2- over assembly tool - T10399/1- .
2. Seals 81
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– Drive oil seal in to stop with assembly device - T10399- .

Installing large oil seal
– Place oil seal -1- over thrust piece - T10400- .
Spring -arrow- faces away from thrust piece.

– Drive in seal to stop.
– Now twist thrust piece in gearbox before starting to pull it out.

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3 Components of bevel box

⇒ “3.1 Assembly overview - components of bevel box”,
page 83
⇒ “3.2 Renewing bevel box seals”, page 85
⇒ “3.3 Renewing needle bearing (polygon bearing) for stub shaft”,
page 97
3.1 Assembly overview - components of

bevel box
(Seals, stub shaft bearing, output flange in bevel box)
1 - Seal
❑ Between bevel box and
bevel box
❑ To renew, remove bevel
box ⇒ page 36
2 - Seal
❑ Between bevel box and
bevel box
❑ To renew, remove bevel
box ⇒ page 36
3 - Plug
❑ With captive seal
❑ 15 Nm
4 - Cap
❑ Drive in to stop with
spacer tube - VW 540
1B- .
5 - Seal
❑ For right stub shaft to
drive shaft
❑ Seal can be renewed
with bevel box installed
6 - Bevel box
⇒ page 36
7 - Cap
❑ To vent bevel box
8 - Breather pipe Volkswagen Technical Site: http://vwts.ru http://vwts.info
❑ To vent bevel box
❑ Press in until stop is reached
9 - Retaining ring
❑ Insert in circumferential groove in stub shaft
3. Components of bevel box 83

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10 - O-ring
11 - Right stub shaft
❑ To remove and install, remove bevel box ⇒ page 36
12 - Needle bearing (polygon bearing)
❑ Needle bearing (polygon bearing) is difficult to turn with stub shaft removed. The fact it is difficult to move
does not mean that the bearing is defective. An acoustic test can only be performed with the bearings
installed.
❑ Inspect for signs of damage to bearings, such as cracking in outer race, and renew if necessary.
13 - Retaining ring
❑ Renew after removal.
❑ For needle roller bearing (polygon bearing)
14 - Hexagon nut
❑ Renew after removal.
❑ Removing ⇒ page 95
❑ Install using locking fluid - D 000 600-
❑ Installing ⇒ page 96
❑ 480 Nm
15 - Output flange
16 - Cover
❑ Not fitted in all bevel boxes
❑ Renew after removing output flange if damaged
❑ Engage with output flange
17 - Seal
❑ For output flange
❑ To renew, remove bevel box ⇒ page 36
18 - Bolt
❑ Tighten diagonally and alternately
❑ 25 Nm
19 - Pinion housing
❑ With shaft bevel gear and inner race/tapered roller bearing
❑ No replacement parts available for these components
❑ Carefully lever off and drive in alternately
❑ Observe bolt holes; pinion housing fits only in one position.
20 - O-ring
❑ Renew after removing pinion housing
❑ To renew, unscrew bolts ⇒ Item 18 (page 84) and carefully lever off pinion housing at projecting webs
on outside edge
❑ Do not remove hexagon nut ⇒ Item 14 (page 84) and output flange ⇒ Item 15 (page 84)

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3.2 Renewing bevel box seals

⇒ “3.2.1 Renewing left seal between bevel box and gearbox on
bevel box”, page 85
⇒ “3.2.2 Renewing seal on right of bevel box”, page 88
⇒ “3.2.3 Renewing bevel box output flange oil seal (bevel box
removed)”, page 92
3.2.1 Renewing left seal between bevel box

and gearbox on bevel box
♦ Multipurpose tool - VW 771/37-
♦ Removal tool - T20143-

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♦ Thrust piece -T10380-
Note
Seals (Qty. 2) can be renewed only with bevel box removed. Al‐
ways renew both seals.
Removing
Remove »outer« seal.
– Lever out seal using puller hook - T20143/2- .
Remove »inner« seal.
Note
So that new seal will not be damaged later on:

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– Remove retaining ring -1- from stub shaft.

– Carefully use plastic mallet -2- to drive stub shaft out in direc‐
tion of arrow.
– Pull out seal for stub shaft on gearbox side.

Installing
Drive in »outer« seal.
– Half-fill space between sealing lip and dust lip of new seal
-arrow- with sealing grease - G 052 128 A1- .
– Lightly oil outer circumference of new oil seal.

Drive in »inner« seal.

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– Half-fill space between sealing lip and dust lip of new seal
-arrow- with sealing grease - G 052 128 A1- .

– Carefully use plastic mallet to drive in stub shaft to stop.
– Fit new retaining ring -1- on stub shaft.

3.2.2 Renewing seal on right of bevel box

♦ Removal tool - T20143-

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♦ Hub grease cap puller - VW 637/2-
♦ Drip tray - V.A.G 1306-
♦ or drip tray for workshop hoist - VAS 6208-

♦ Sealing grease
♦ Grease for splines
♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
Note
Seal can be renewed with bevel box installed.
Removing
– Raise vehicle.
– Remove noise insulation beneath engine/gearbox ⇒ General
body repairs, exterior; Rep. gr. 66 ; Noise insulation; Assem‐
bly overview - noise insulation .

Arteon 2018 ➤
– If fitted, remove drive shaft heat shield -1- from bevel box
-arrows- ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive
shaft; Removing and installing drive shaft heat shield .
Right drive shaft heat shield is secured with 2 or 3 nuts.
– Remove right drive shaft. ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft
1782- underneath.
– Remove retaining ring -arrow A- and O-ring -arrow B- from

stub shaft.
Note
Some bevel boxes have protective cap -arrow- installed on right.

Renew protective cap each time after removing.
Pull off protective cap.
– Position hub grease cap puller - VW 637/2- in recess -arrow-

and lever off protective cap.

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– Lever out seal.
Installing
– Half-fill space between sealing lip and dust lip -arrow- with
sealing grease .

– Fit new retaining ring and new seal on stub shaft.
Bevel box with protective cap
– Drive on new protective cap to stop.

– Then install retaining ring -arrow A- and O-ring -arrow B-.

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– Grease splines of stub shaft using grease for clutch plate

splines .
– Install drive shaft ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shaft; Removing and installing drive shafts .
– Install drive shaft heat shield -1- ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40 ; Drive shaft; Removing and installing drive
shaft heat shield .
gr. 66 ; Noise insulation; Assembly overview - noise insula‐
tion .
3.2.3 Renewing bevel box output flange oil

seal (bevel box removed)
The output flange is secured with a nut -A-.
Disregard -B- and -arrows-.

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equipment required
♦ Support clamp - VW 313-

♦ Tube - VW 516-
♦ Thrust plate - 40-105-
♦ Gearbox support - T10108-
♦ Support plate - T10108/1-

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♦ Two-arm puller - VAS 251 001- or e.g. two-arm puller - Kukko
20/10-
♦ Three-arm puller - VAS 251 205- or e.g. three-arm puller -
Kukko 45-2-
♦ Extractor hook - VW 771/37-
♦ Sealing grease
♦ Universal grease
♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
♦ 2 bolts M10 x 30
♦ 4 nuts M12 x 10
Note
The bevel box oil seal for the output flange can only be renewed
with the bevel box removed.

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– Fit bevel box on gearbox support - T10108- onto hole

-arrow- marked with the number -5-.
A - Lay nuts M12 x 10 (qty. 4) between bevel box and gearbox
support . Nuts function as spacers.
– Then align bevel box with hole opposite and secure.
– Place drip tray underneath.
– Drain oil from bevel box.
– Lock output flange for bevel box with stop plate - T10108/1- .
Screw in M10 x 30 bolts -arrows- to do this.
Removing hexagon nut for output flange

A - 36 mm socket for 3/4" drive
– Swing bevel box so that output flange points upwards.

– Pull output flange off shaft bevel gear of bevel box.
A - Three-arm puller - VAS 251 205- or e.g. three-arm puller -
Kukko 45-2-
– Pull out seal -A- for output flange.

– Clean residual locking fluid from thread of shaft bevel gear.
– Clean any oil seal residue away from area on shaft bevel gear.

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Installing
– Drive in new oil seal to stop using thrust piece - T10049- .
– Half-fill space between sealing lip and dust lip with sealing
grease .
– Lightly lubricate splines of output shaft with universal grease .
– Pull in output flange using two arm puller -A-.

A - Two-arm puller - VAS 251 001- or e.g. two-arm puller - Kukko
20/10-
Please note the following:
• Use new or nearly new puller hooks!
• The output flange must not be canted.
• Fit puller hooks as far as they will go onto underside of pinion
housing.
• Take up slack on puller hooks fully with two arm puller
-arrows-.
• Puller hooks should not bend outwards.
• If necessary, halt pulling process, pull off output flange again
and restart pulling process.
Coat thread of new hexagon nut with locking fluid D 000 600
– Tightening new hexagon nut for output flange to specified tor‐
que.
Specified torque ⇒ Item 14 (page 84)
A - 36 mm socket for 3/4" drive

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Measure radial run-out on output flange/shaft bevel gear.
Note
After the output flange nut has been tightened, the radial run-out
on the centring pin of the shaft bevel gear must be checked.
– Secure measuring tools with bolt -A- (M8 x 25) on bevel box.
– Fit dial gauge - VAS 6080- on centring pin of shaft bevel gear
-B- and set it to “0” with 1 mm preload.
– Turn output flange one full turn in -direction of arrow-.
– Read measured value on dial gauge.
• Max. radial run-out = 0.07 mm.
– Check gear oil level in bevel box ⇒ page 72 .
Specified torques
♦ ⇒ page 83
3.3 Renewing needle bearing (polygon bearing) for stub shaft

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equipment required
♦ Pressure plate - VW 401-

♦ Pressure plate - VW 402-
♦ Press piece - VW 407-
♦ Press tool - VW 412-
♦ Assembly tool - 3253/5-
♦ Tensioning device - T10047-

♦ Thrust pieces for drive pinion bearing - VW 470-
♦ Socket - T10107 A-
♦ -3- splitter 2275 mm , e.g. -Kukko 17/1-

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Removing
– Remove noise insulation below engine and gearbox. ⇒ Gen‐
eral body repairs, exterior; Rep. gr. 66
– Remove retaining ring -1- from stub shaft.
– Carefully use plastic mallet -2- to drive stub shaft out in direc‐
tion of arrow.
– Align both parts of tool so that marks “B” are opposite one
another.
– The shoulders -arrows- must then be below the bearing.
– Now screw both halves together to stop.
– Lever off retaining ring -A- for needle bearing.

– To avoid damage to running surface of bearing on shaft, turn
shaft during pressing procedure -arrow-.
Installing
– Align both parts of tool so that marks “B” are opposite one
another.

Arteon 2018 ➤
– To avoid damage to running surface of bearing on shaft, turn

shaft during pressing procedure -arrow-.
– Secure needle bearing with a new retaining ring.
– Carefully use plastic mallet to drive in stub shaft to stop.
– Fit new retaining ring -1- on stub shaft.

– Install right drive shaft ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Drive shaft; Removing and installing drive shaft .
– Install heat shield. Specified torque ⇒ Running gear, axles,

steering; Rep. gr. 40 ; Drive shaft; Removing and installing
drive shaft heat shield
– Check oil level in bevel box ⇒ page 72 .
tion .

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4 Gearbox control system
4.1 Removing and installing gearbox control

unit
Fitting location: automatic gearbox control unit - J217- is located
in plenum chamber.
Removing
– Remove windscreen wiper arms ⇒ Electrical system; Rep. gr.
92 ; Windscreen wiper system; Removing and installing wind‐
screen wiper arms .
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Plenum chamber cover; Removing and
installing plenum chamber cover .
– Push retaining tabs -arrows- upwards and pull control unit to
left out of bracket -left arrow-.
– Release connector and pull off control unit.
Installing
– Fit and lock connector onto control unit.
– Insert control unit from left into bracket and engage using re‐
taining tabs.
4. Gearbox control system 101

8 Speed Automatic Gearbox 09p Eng

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Service

Service Department. Technical Information

8.8 Removing and installing multifunction switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

1.1 General safety provisions

Risk of injury and accident by accidental engagement of gear

1.2 Notes on tow-starting/towing

Danger of irreparable damage to gearbox.

It is not possible to tow-start the engine.

2.1 Gearbox identification

Code letter -arrow 1-

2.2 Identification of torque converter

2 Rep. gr.00 - Technical data

3.1 General repair instructions

Guided Fault Finding, vehicle self-diagnosis and test instruments

3.2 Gaskets and seals

3.3 Nuts and bolts

4 Rep. gr.00 - Technical data

4.1 Allocation gearbox - engine

4.1.1 Identification codes, assembly alloca‐

4.1.2 Identification codes, assembly alloca‐

4.2.1 8-speed automatic gearbox 09P, front-wheel drive

4.2.2 8-speed automatic gearbox 09P, all-wheel drive

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

5.1 Overview of fitting locations - electrical

6 Rep. gr.00 - Technical data

Multifunction switch - F125-

Wiring harness for senders and solenoid valves

Gearbox input speed sender - G182- and gearbox output speed

8 Rep. gr.00 - Technical data

1.1 Assembly overview - torque converter

Securing torque converter to prevent it from falling out

1.2 Removing and installing torque convert‐

– Pull torque converter forwards from gearbox and lay it on a

If engine and gearbox are brought together with force because

During subsequent installation, observe the following in particu‐

10 Rep. gr.32 - Torque converter

Before and when tightening bolts on engine/gearbox flange,

– Install gearbox ⇒ page 28 .

1.3 Draining torque converter

If ATF is contaminated, drain torque converter as follows:

1.4 Removing and installing torque convert‐

♦ Removal tool - VW 681-

12 Rep. gr.32 - Torque converter

1.1 Assembly overview - ATF circuit

1.2 Removing and installing ATF cooler

1.2.1 Removing and installing ATF cooler

♦ Hose clamps - 3094-

♦ Engine bung set - VAS 6122-

♦ Pliers for spring-type clips

♦ Mark coolant hoses to ATF cooler to prevent interchanging

14 Rep. gr.37 - Controls, housing

– Clamp off coolant hoses using hose clamps up to 25 mm -

– Unscrew bolts -arrows-, and remove ATF cooler.

Always renew O-rings.

– Connect coolant hoses to ATF cooler according to marks

2.1 Checking ATF level

♦ Adapter for oil filling - VAS 6262 A-

♦ Adapter - VAS 6262/2-