Servicing Multitronic 0AW

Service
Servicing multitronic 0AW

Edition 04.2016
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
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.
D3E8033D012
Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Servicing multitronic 0AW - Edition 04.2016
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Common faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
37 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1 ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Purging ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3 Securing to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
38 - Gears, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.1 Exploded view - dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2 Exploded view - end cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.3 Exploded view - input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.4 Removing and installing dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.5 Removing and installing end cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.6 Cleaning selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.7 Modifying thrust piece T40099 for use with multitronic gearbox 0AW, front-wheel drive . . 24
1.8 Removing and installing input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.9 Removing and installing input shaft cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.10 Renewing ball bearing for input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.1 Exploded view - reverse gear clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.2 Exploded view - input shaft with friction plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.3 Removing and installing reverse gear clutch and determining shim thicknesses . . . . . . . . 40
2.4 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.5 Adjusting input shaft and checking clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.6 Assessing wear on input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

1 Final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.1 Exploded view - final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.1 Renewing oil seal (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.2 Renewing oil seal (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.3 Renewing oil seal for input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.4 Renewing selector shaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.1 Removing and installing flange shaft (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.2 Removing and installing flange shaft (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.3 Preload of ball bearing for flange shaft (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.4 Renewing mounting bracket and ball bearing for flange shaft (left-side) . . . . . . . . . . . . . . 85
4 Gearbox control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.1 Removing and installing gearbox control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.2 Removing and installing hydraulic control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Contents i
ii Contents
00 – Technical data
1 Repair instructions
(ARL004728; Edition 04.2016)
⇒ “1.1 General repair instructions”, page 1
⇒ “1.2 Contact corrosion”, page 2
⇒ “1.3 Rules for cleanliness”, page 3
⇒ “1.4 Common faults”, page 3
1.1 General repair instructions

Proper tools and the maximum possible care and cleanliness are
essential for satisfactory repairs to the transmission units. The
usual basic safety precautions also naturally apply when carrying
out repair work.
A number of generally applicable instructions for the various re‐
pair procedures - which were previously repeated at numerous
places in the Workshop Manual - are summarised here. They ap‐
ply to the work described in this Manual.
Gearbox
♦ Observe rules for cleanliness when working on gearbox
⇒ page 3 .
♦ Clean ATF lines and ATF cooler after performing repairs on
the gearbox ⇒ multitronic 0AW, front-wheel drive; Rep. gr.
37 ; ATF circuit; Exploded view - ATF circuit .
♦ Components to be re-used must be cleaned, checked and if
necessary renewed prior to installation
⇒ “2.6 Assessing wear on input shaft”, page 60 .
After fitting the gearbox, check the following fluid levels and top
up if necessary:
♦ ATF level ⇒ multitronic 0AW, front-wheel drive; Rep. gr. 37 ;
ATF; Checking ATF level .
♦ Gear oil in front final drive ⇒ multitronic 0AW, front-wheel
drive; Rep. gr. 39 ; Gear oil; Checking gear oil level .
♦ Capacities ⇒ multitronic 0AW, front-wheel drive; Rep. gr. 00 ;
Technical data; Capacities .
♦ Specifications ⇒ Electronic parts catalogue .
O-rings, seals, oil seals and gaskets
♦ Always renew O-rings, seals, oil seals and gaskets.
♦ After removing gaskets and seals, always inspect the contact
surface on the housing or shaft for burrs resulting from removal
or for other signs of damage.
♦ The open side of the oil seals faces toward the side with fluid
filling.
♦ Lightly lubricate the outer circumference and sealing lip of
seals with ATF before installing.
♦ Lightly lubricate O-rings with ATF or vaseline before installa‐
tion to prevent them getting crushed during assembly.
♦ Use only ATF or vaseline on all parts running in ATF. Other
lubricants will cause malfunction of the gearbox hydraulics.
1. Repair instructions 1
♦ When installing a new oil seal, position the seal in the housing
so that the sealing lip does not contact the shaft in the same
place as the old seal (make use of installation depth toleran‐
ces).
♦ Renew paper gaskets, clean all sealing surfaces thoroughly
and remove previous gaskets completely.
Nuts, bolts
♦ Slacken bolts in reverse sequence to the specified tightening
sequence.
♦ Nuts and bolts which secure covers and housings should be
loosened and tightened in diagonal sequence and in stages if
no tightening sequence is specified.
♦ The tightening torques stated apply to non-oiled nuts and
bolts.
♦ Always renew self-locking bolts and nuts.
Locking elements
♦ Do not over-stretch circlips.
♦ Always renew circlips which have been damaged or over-
stretched.
♦ Circlips must be properly seated in the base of the groove.
♦ Renew spring pins. Installation position: slot must be in line
with direction of force.
Bearings
♦ Lightly lubricate bearings with ATF before inserting.
♦ Fit bearings and shims loosely with vaseline only. Other types
of lubricant will cause the gearbox hydraulics to malfunction.
Shims
♦ Use a micrometer to measure the shims at several points. Dif‐
ferent shim thicknesses make it possible to obtain the exact
shim thickness required; if necessary, fit 2 shims.
♦ Check for burrs and damage. Install only shims which are in
perfect condition.
1.2 Contact corrosion

General information:
♦ Contact corrosion can occur if unsuitable fasteners are used
on the vehicle (bolts, nuts, washers etc.).
♦ For this reason, only fasteners with a special surface coating
are fitted.
♦ Rubber or plastic parts and adhesives also consist of non-
conductive materials.
♦ If you are not sure whether used parts can be re-installed, al‐
ways fit new parts ⇒ Electronic parts catalogue .
Please note:
♦ Use only genuine spare parts: these have been fully tested
and are compatible with magnesium.
♦ We recommend the use of accessories approved by Audi.
♦ Damage resulting from contact corrosion is not covered by the
warranty.
2 Rep. gr.00 - Technical data

1.3 Rules for cleanliness

♦ Thoroughly clean all joints and connections and the surround‐
ing areas before dismantling.
♦ Use cleaning fluid - D 009 401 04- to clean the gearbox and
its components.
♦ Use lint-free cloths for cleaning, such as the “WYPALL X70 /
WORKHORSE” cloth from Kimberly-Clark Professional.
♦ Seal off open lines and connections immediately with clean
plugs or sealing caps from engine bung set - VAS 6122- im‐
mediately.
♦ Place removed parts on a clean surface and cover them over.
Use sheeting or lint-free cloths.
♦ Carefully cover or seal open components if repairs cannot be
carried out immediately.
♦ Only install clean components: do not remove replacement
parts from packaging until just before installation.
♦ Protect unplugged electrical connectors against dirt and mois‐
ture and make sure connections are dry when attaching.
1.4 Common faults
Note
♦ Before commencing fault-finding, interrogate event memory of

automatic gearbox control unit -J217- using vehicle diagnostic
tester .
♦ In addition, interrogate event memory of engine control unit,
because faults detected by the engine control unit can also
cause malfunctions of the gearbox .
♦ Use the “Guided Fault Finding” mode with vehicle diagnostic
tester .
♦ Also use all the indicated “Technical product information” (TPI)
in the ⇒ Technical Service Handbook (HST)
♦ When assessing complaints and abnormal wear, refer to the
training documentation ⇒ EX 335 “multitronic”, Part 2 .
♦ Before commencing fault-finding, check ATF level ⇒ multi‐
tronic 0AW, front-wheel drive; Rep. gr. 37 ; ATF; Checking
ATF level .
1. Repair instructions 3
37 – Controls, housing
1 ATF
⇒ “1.1 Purging ATF”, page 4
1.1 Purging ATF

⇒ “1.1.1 ATF purging procedure”, page 4
⇒ “1.1.2 Draining ATF (for ATF purging procedure)”, page 5
⇒ “1.1.3 Filling up with ATF (for ATF purging procedure)”,
page 8
⇒ “1.1.4 Road test (for ATF purging procedure)”, page 11
1.1.1 ATF purging procedure

Special tools and workshop equipment required
♦ Vehicle diagnostic tester
Procedure
A normal ATF change involves replacing only approx. 55 ... 60 %
of the total ATF in the gearbox.
The “ATF purging procedure” has to be employed if all the old
ATF in the gearbox is to be removed.
ATF purging is always necessary when performing the following
work:
♦ Renewing the input shaft
♦ Servicing the input shaft
This involves performing the road test twice, as described below,
and then changing the ATF.
This is the only way to ensure complete renewal of the ATF in the
gearbox.
The work required for the ATF purging procedure is described
below in seven steps.
Caution
Risk of damage to gearbox

♦ It is important to exactly follow all the described steps.
– Fill up with ATF after installing gearbox

⇒ “1.1.3 Filling up with ATF (for ATF purging procedure)”, page
8.
Purging ATF
1. ⇒ “1.1.4 Road test (for ATF purging procedure)”,
page 11 .
2. ⇒ “1.1.2 Draining ATF (for ATF purging procedure)”,
page 5 .
3. ⇒ “1.1.3 Filling up with ATF (for ATF purging procedure)”,
page 8 .
4. ⇒ “1.1.4 Road test (for ATF purging procedure)”,
page 11 .
4 Rep. gr.37 - Controls, housing

5. ⇒ “1.1.2 Draining ATF (for ATF purging procedure)”,

page 5 .
6. ⇒ “1.1.3 Filling up with ATF (for ATF purging procedure)”,
page 8 .
7. Check and correct ATF level ⇒ multitronic 0AW, front-wheel
drive; Rep. gr. 37 ; ATF; Checking ATF level .
Note
Observe all notes and test requirements for “Checking and cor‐
recting ATF level”.
Checking the ATF level completes the purging procedure.
1.1.2 Draining ATF (for ATF purging proce‐

dure)
♦ Hook - 3438-
♦ Used oil collection and extraction unit - V.A.G 1782-
♦ Safety goggles
Procedure
Caution

♦ The engine must not be started when the ATF has been
partly or completely drained from the gearbox.
1. ATF 5
• Engine not running.

• Vehicle must be absolutely horizontal (drive it onto a four-pillar
lifting platform or over an inspection pit).
• Selector lever at position “P”.
• Electromechanical parking brake applied.
• Different versions have ATF inspection plugs -A- of different
lengths. The ATF inspection plug must be renewed after
checking the ATF level. Always select correct version accord‐
ing to gearbox code letters in ⇒ Electronic parts catalogue .
To prevent damage to the gearbox, please check the new ATF
inspection plug by comparing it with the old one.
– Remove rear noise insulation ⇒ General body repairs, exte‐

rior; Rep. gr. 66 ; Noise insulation; Removing and installing
noise insulation .
– Place used oil collection and extraction unit - V.A.G 1782- be‐
low gearbox.
WARNING
Risk of eye injury.

♦ Wear safety goggles.
– Unscrew ATF inspection plug -A-.

– Drain ATF.
Note
♦ Please observe requirements for disposal.

♦ Different versions have different ATF inspection plugs and dif‐
ferent fluid level pipes. Always select correct version accord‐
ing to gearbox code letters in ⇒ Electronic parts catalogue .

Gearbox with long, curved fluid level pipe:

– Pull fluid level pipe -A- out of ATF inspection hole using hook
- 3438- and allow remaining ATF to drain off.
– Press fluid level pipe -A- into ATF inspection hole -B- by hand.
• Installation position: large lug -1- on fluid level pipe should face
recess -2- in ATF inspection hole.
Note
The fluid level pipe -A- must be renewed after the second filling.
Gearbox with short, straight fluid level pipe:

– Pull fluid level pipe -A- out of ATF inspection hole using hook
- 3438- and allow remaining ATF to drain off.
1. ATF 7
• O-ring -1- must be correctly fitted in groove on fluid level pipe.

– Carefully press fluid level pipe -A- into ATF inspection hole
-B- by hand, taking care to keep pipe straight.
Note
♦ O-ring on fluid level pipe -A- provides seal between this pipe
and fluid level pipe -C-. Only then can the ATF level be topped
up correctly.
♦ The fluid level pipe -A- must be renewed after the second fill‐
ing.
♦ Disregard -3438- .
– Continue ATF purging procedure ⇒ page 4 .
1.1.3 Filling up with ATF (for ATF purging pro‐

cedure)

♦ ATF charging device for CVT gearboxes - VAS 5162-
Preparations:
• ATF drained
Caution

♦ Only the ATF available as a replacement part for the “mul‐
titronic 0AW” gearbox may be used.
♦ Other, non-approved types of ATF or other oils cause
malfunctions and/or failure of the gearbox.
♦ For the correct type, refer to ⇒ Electronic parts catalogue .
♦ The ATF charging device must be clean and the ATF must
not be mixed with other types of ATF!
Note
♦ The illustration on the reservoir of the ATF charging device for

CVT gearboxes - VAS 5162- displays a warning in the top left
corner to use ONLY the ATF specially formulated for CVT
gearboxes.
♦ The illustration also shows the steps to follow when filling up;
these are also described below.
Procedure
– Fill ATF charging device for CVT gearboxes - VAS 5162- with
ATF for “multitronic 0AW” gearbox.
– Secure filled reservoir for ATF charging device as high as
possible on vehicle.
• The stopcock on ATF charging device for CVT gearboxes -
VAS 5162- must be closed.
Caution

♦ The engine must not be started when the ATF has been
partly or completely drained from the gearbox.
♦ In this case you need to fill the gearbox first with 5.5 … 6
litres of ATF.
1. ATF 9
– Remove O-ring -1- at connection -2- on ATF charging device

for CVT gearboxes - VAS 5162- .
Caution
There is a risk of filling the gearbox incorrectly.

♦ The connection -2- must be screwed hand-tight all the way
into the inspection hole on the gearbox with the O-ring re‐
moved.
♦ The O-ring must be removed at the connection -2- so that
the fluid level pipe in the inspection hole can be pressed
into the upper position.
♦ Only then can the ATF level be checked and topped up to
the maximum correctly.

– With O-ring removed, screw connection of ATF charging de‐

vice for CVT gearboxes - VAS 5162- hand-tight all the way into
threaded hole for ATF inspection plug.
Note
This will push the fluid level pipe into the correct installation po‐
sition.
– Turn stopcock in direction of filling hose -lower arrow-. ATF

flows into gearbox.
– Fill gearbox with at least 5.5 … 6 ltr. of fresh ATF.
– Shift selector lever into position “P”.
Caution
Rev engine up to approx. 2500 rpm immediately after starting.

♦ The engine must be revved up to vent air from the ATF
pump after performing repairs on the gearbox.
♦ If the engine is not revved up, the pump will run briefly
without ATF and may be damaged.
– Start engine.
– Press accelerator pedal to rev engine briefly up to 2500 rpm.
– Press and hold brake pedal.
– Shift through all selector lever positions “P, R, N, D, S” and
leave for approx. two seconds in each position with engine
running at idling speed.
– Move selector lever to position “P” and allow engine to con‐
tinue running at idling speed.
– Unscrew connecting piece on stopcock of ATF charging de‐
vice for CVT gearboxes - VAS 5162- from opening for ATF
inspection plug.
– Allow excess ATF to drain off.
– Tighten old ATF inspection plug again.
• Tightening torque: 30 Nm
– After second filling: Check ATF level and top up ⇒ multitronic
0AW, front-wheel drive; Rep. gr. 37 ; ATF; Checking ATF lev‐
el .
Note
Observe all notes and test requirements for “Checking and cor‐
recting ATF level”.
1.1.4 Road test (for ATF purging procedure)

• ATF topped up ⇒ page 8 .
1. ATF 11
Caution
Do not run the engine or tow the vehicle when there is no ATF
in the gearbox.
– Drive vehicle off lifting platform.
Note
Observe notes on raising and lowering for vehicles with air sus‐
pension ⇒ Running gear, front-wheel drive and four-wheel drive;
Rep. gr. 00 ; Repair notes; Raising and lowering vehicle when air
spring system has / has not been opened .
– Follow these instructions exactly and observe all safety pre‐

cautions.
WARNING
When road-testing the vehicle as described below, observe all

statutory regulations for driving on public roads. In some cases
it may be necessary to drive the vehicle in a closed test area.
– Start engine.
– Shift selector lever to position “D”.
– Shift selector lever into “tiptronic” gate.
– Accelerate vehicle by pressing accelerator lightly.
– Watch gear display in instrument cluster.
– Shift through gears from 1st to top gear by moving selector
lever to “+”.
– Then shift back to 1st gear by moving selector lever to “–”.
Note
Press brake pedal if necessary.
– Press brake pedal and brake wheels to 0 km/h.

– Shift selector lever to position “R”.
– Accelerate vehicle to 20 km/h by pressing accelerator lightly.
– Press brake pedal and brake wheels to 0 km/h.
– Shift selector lever back to position “D” and repeat complete
procedure five times.
Note
The complete test cycle has to be repeated five times to ensure

that all the old ATF is mixed with the new ATF.
– Finally, shift selector lever to position “P” and switch off engine.

Caution

♦ Filling up the ATF as part of the ATF purging procedure is
not a substitute for checking the ATF level.
♦ After completing the ATF purging procedure, the ATF level
must be checked and adjusted ⇒ multitronic 0AW, front-
wheel drive; Rep. gr. 37 ; ATF; Checking ATF level .
1. ATF 13
2 Transporting gearbox
♦ Shackle - 10 - 222 A /12-
♦ Workshop hoist - VAS 6100-
Procedure
– Attach shackle - 10 - 222 A /12- to upper web of gearbox
housing and secure in place.
– Engage hook of workshop hoist - VAS 6100- as shown in il‐
lustration.
– Lift gearbox with workshop hoist - VAS 6100- and shackle - 10
- 222 A /12- .

3 Securing to engine and gearbox sup‐

port
♦ Hook - 10 - 222 A /2-
♦ Engine and gearbox support - VAS 6095-
♦ Bracket - T10358-
♦ Gearbox support - T40206- with -T40206/1-
♦ Bolt M8x30, nut, 2x washer
3. Securing to engine and gearbox support 15

Procedure
• ATF drained ⇒ multitronic 0AW, front-wheel drive; Rep. gr.
37 ; ATF; Draining and filling ATF
• Gear oil drained ⇒ multitronic 0AW, front-wheel drive; Rep.
gr. 39 ; Gear oil; Draining and filling gear oil
– Bolt gearbox support - T40206- with -T40206/1- to gearbox as
shown in illustration.
– Secure bracket - T10358- to lifting eye on right side of gearbox
with M8x30 bolt -item 1-, nut and 2 washers.
– Attach workshop hoist - VAS 6100- to bracket - T10358- with
hook - 10 - 222 A /2- .
– Lift gearbox and insert into engine and gearbox support - VAS
6095- .

38 – Gears, control
1 Dismantling and assembling gearbox
⇒ “1.1 Exploded view - dual-mass flywheel”, page 17
⇒ “1.2 Exploded view - end cover”, page 18
⇒ “1.3 Exploded view - input shaft”, page 19
⇒ “1.4 Removing and installing dual-mass flywheel”, page 19
⇒ “1.5 Removing and installing end cover”, page 21
⇒ “1.6 Cleaning selector shaft”, page 23
⇒ “1.7 Modifying thrust piece T40099 for use with multitronic
gearbox 0AW, front-wheel drive”, page 24
⇒ “1.8 Removing and installing input shaft”, page 24
⇒ “1.9 Removing and installing input shaft cover”, page 30
⇒ “1.10 Renewing ball bearing for input shaft”, page 35
1.1 Exploded view - dual-mass flywheel
1 - Dual-mass flywheel
❑ ⇒ “1.4 Removing and in‐
stalling dual-mass fly‐
wheel”, page 19
2 - Gearbox housing
3 - Oil seal for input shaft
❑ ⇒ “2.3 Renewing oil seal
for input shaft”,
page 70
4 - Bolt
❑ Renew
❑ 4-cyl. engines: 3x
❑ 6x for 6-cyl. engines and
Audi A6/A7 with 2.0 ltr.
TDI engine
❑ Tightening torque and
sequence ⇒ multitronic
0AW, front-wheel drive;
Rep. gr. 37 ; Removing
and installing gearbox;
Installing gearbox
1. Dismantling and assembling gearbox 17

1.2 Exploded view - end cover
Caution

♦ Do not run engine or tow vehicle with end cover removed
or when there is no ATF in the gearbox.
Note
♦ ⇒ “1 Repair instructions”, page 1 .

♦ ⇒ “1.3 Rules for cleanliness”, page 3 .
1 - Gearbox
2 - Axial sealing element, small
❑ Renew
3 - Axial sealing element, large
❑ Renew
4 - Roller
5 - Lever
❑ For selector shaft detent
6 - Spring
7 - Seal
❑ For connector on auto‐
matic gearbox control
unit - J217-
8 - Bolt
❑ Renew
❑ 12x, tighten diagonally
❑ 10 Nm +90°
9 - End cover
❑ Removing and installing
(with gearbox installed)
⇒ multitronic 0AW,
front-wheel drive; Rep.
gr. 38 ; Dismantling and
assembling gearbox
stalling end cover”,
page 21
10 - Gasket
❑ Renew
11 - Bolt
❑ 3x
❑ 5 Nm + 90°
12 - Automatic gearbox control unit - J217-
❑ ⇒ “4.1 Removing and installing gearbox control unit”, page 88
18 Rep. gr.38 - Gears, control

13 - Bolt
❑ 3x
❑ 5 Nm + 90°
14 - Hydraulic control unit
❑ ⇒ “4.2 Removing and installing hydraulic control unit”, page 90
1.3 Exploded view - input shaft
1 - Input shaft
stalling input shaft”,
page 24
2 - Cover
❑ For input shaft
stalling input shaft cov‐
er”, page 30
3 - O-ring
❑ Renew
4 - Ball bearing
❑ For input shaft
❑ ⇒ “1.10 Renewing ball
bearing for input shaft”,
page 35
5 - Circlip
❑ Measure
❑ Renew
6 - Oil seal
❑ For input shaft
for input shaft”,
page 70
7 - Circlip
❑ Different versions, al‐
ways renew
❑ Determining thickness
⇒ page 30
1.4 Removing and installing dual-mass fly‐

wheel

♦ Extractor - T40176-
♦ Grease for clutch plate splines - G 000 100-

♦ Sealing grease - G 052 128 A1-
Removing
• Gearbox secured to engine and gearbox support ⇒ page 15 .
– Remove flange shaft (left-side) ⇒ multitronic 0AW, front-wheel
drive; Rep. gr. 39 ; Differential; Removing and installing flange
shaft (left-side) .
– Attach extractor - T40176- to dual-mass flywheel -A- using nut
-B- -arrow-.
– Turn extractor - T40176- upwards.
Note
Keep hold of the bottom of the dual-mass flywheel, as shown in

the illustration, to prevent it from tilting over.
– Pull dual-mass flywheel off input shaft -arrow- keeping dual-

mass flywheel straight.
Caution
Take care not to damage flange for drive plate on dual-mass

flywheel.
♦ Do not lay down the dual-mass flywheel so that it rests on
the flange -arrow- for the drive plate.
♦ This could bend the flange -arrow- for the drive plate,
which would cause problems with clutch operation.
– Put dual-mass flywheel down carefully, e.g. on work bench.

Installing
Installation is carried out in reverse sequence; note the following:
– Thoroughly clean area of clutch housing leading to differential
-arrow A-, and oil seal -arrow B-.
Note
If oil seal between differential and gearbox housing -arrow B- is

damaged, it must be renewed ⇒ page 66 .
– Pack space between sealing lip and dust lip half-full with seal‐
ing grease - G 052 128 A1- .
– Clean input shaft -arrow-.

– Apply a thin coating of grease for clutch plate splines -
G 000 100- to splines on input shaft.
– Carefully slide dual-mass flywheel onto input shaft -arrow-,

taking care to keep dual-mass flywheel straight.
– Install flange shaft (left-side) ⇒ page 75 .
1.5 Removing and installing end cover
Note
The end cover can also be removed and installed with the gear‐
box in the vehicle ⇒ multitronic 0AW, front-wheel drive; Rep. gr.
38 ; Dismantling and assembling gearbox .

Removing
• Gearbox must be removed and secured to engine/gearbox
support in horizontal position ⇒ page 15 .
low gearbox.
– Remove bolts -arrows- and take off end cover.
Installing
• Tightening torques
Note
♦ Renew seals, gaskets and axial sealing elements.

♦ Renew bolts for end cover.
♦ Do not touch pins in connector -A- with bare hands.
– Slide new seal -B- onto connector -A- of automatic gearbox

control unit - J217- , with twin lips facing outwards.
– If fitted, attach displacer plate -A- to automatic gearbox control

unit - J217- .
– Clean sealing surfaces on gearbox housing and end cover.
– Dowel sleeves in gearbox housing or end cover must be re-
fitted in same places.
– Place new gasket for end cover onto gearbox housing.
Note
Make sure dowel sleeves are correctly seated.

– Fit end cover and make sure that gasket does not move out of
position.
– Check installation position of seal -A-:
• Seal must be flush fitted (the sealing lips must not be kinked).
– Screw in new bolts -arrows- in diagonal sequence until hand-
tight and then tighten to specified torque.
1.6 Cleaning selector shaft

Procedure
• End cover must be removed ⇒ page 21 .
• Automatic gearbox control unit - J217- must be removed
⇒ page 88 .
Note

– Clean selector shaft detents -arrows-. Use lint-free cloths.

When doing so, take particular care to remove metal swarf or
the like from the contact surfaces of the magnets.
Note
Make sure that spring -1- and roller -4- are properly secured.
– Check roller -4- and spring -1- for damage; renew if necessary.

1.7 Modifying thrust piece - T40099- for use

with multitronic gearbox 0AW, front-
wheel drive
Procedure
• Input shaft is removed ⇒ page 24
– Place input shaft on thrust piece - T40099- so it is exactly cen‐
tred.
– Make paint markings -arrow- at the points where the dowel
pins -1- make contact with the top ring of -T40099- .
• The marked positions should be approximately half-way be‐
tween the supports -2- of -T40099- .
– Make a centre punch mark inside the marked area at a dis‐

tance -a- = 6 mm from the inside edge and drill a ∅ 11 mm
hole.
– Make two saw cuts as shown -arrows-.

– Deburr saw cuts and drillings.
1.8 Removing and installing input shaft

♦ Workshop hoist - VAS 6100-

♦ Puller - T40050-
♦ Thrust piece - T40099-
Removing
Note

• Gearbox must be removed and secured in a vertical position

on engine and gearbox support ⇒ page 15 .
• Thrust piece - T40099- must be modified for use with multi‐
tronic gearbox 0AW, front-wheel drive ⇒ page 24 .
– Drain ATF ⇒ page 5 . To do so, swivel gearbox into installation
position (horizontal).
Note
Gearbox must not be turned such that flange points downwards.
– Mark installation position of input shaft cover with paint

-arrows-.

– Remove circlip -1-.
Note
♦ Two different types of circlip are in use.

♦ The current circlips do not have a groove and can only be
prised out using a screwdriver.
– Apply puller - T40050- to input shaft.

– Check that puller is securely attached to input shaft.
• The circlip must be pushed all the way down.
– Use workshop hoist - VAS 6100- and puller - T40050- to pull
input shaft together with cover and forward clutch out of gear‐
box housing -arrow-.
Note
The input shaft cover is difficult to remove from the gearbox hous‐
ing. Apply tension to input shaft with workshop hoist - VAS 6100-
and carefully apply hammer blows to flange of gearbox bellhous‐
ing using plastic hammer and a suitable piece of wood until cover
comes loose.
Caution
A damaged oil pipe will cause problems when driving off from
a standstill or complete gearbox failure.
♦ The input shaft must not be laid down on the projecting oil
pipe -arrow-.

– Place input shaft on thrust piece - T40099- .
Installing
– Assess wear on gearbox components ⇒ page 60 .
– Remove bolts -arrows- and pull ATF filter out of gearbox hous‐
ing.
– Clean sealing surfaces on gearbox housing and input shaft
cover.
– Adjust and install reverse gear clutch ⇒ page 40 .
– Check that dowel sleeves -arrows- (for locating input shaft

cover) are securely fitted.

– Renew axial sealing element -arrow-.

• Installation position: sealing lip faces upwards towards input
shaft cover.
– Renew O-ring for input shaft cover and lubricate lightly with
ATF.
– Align plates of reverse gear clutch using a straight-edge or

similar.
• The teeth must be set exactly in line.
– Check installation dimension of oil pipe -arrow-:

• With oil pipe fully inserted, distance -a- from end of oil pipe to
input shaft should be approx. 11.5 mm.
Note
♦ If the distance is less, the oil pipe may be damaged (the end
could have broken off if the oil pipe was pushed in too far).
♦ If the distance is larger, the oil pipe is not pushed in far enough.
Caution
pipe -arrow-.

– Insert input shaft with input shaft cover in gearbox housing and
align according to marks made before removal -arrows-.
– When doing this, rotate input shaft slightly in both directions
until all reverse gear clutch plates have engaged.
– Using a screwdriver -arrow- inserted through opening in hous‐

ing for ATF filter, rotate gear -1- of intermediate gearing until
it engages with gear on input shaft.
– Check that input shaft cover is flush with gearbox housing.

– After making sure that both components are flush, knock input
shaft cover carefully and uniformly into gearbox housing all
round as far as stop using a plastic hammer and a suitable
piece of wood.

Note
♦ If the original input shaft cover and gearbox housing are being
reinstalled, use a new circlip -1- of the same thickness as that
previously fitted.
♦ If a new input shaft cover and/or gearbox housing are being
installed, you have to determine the thickness of the required
circlip.
Determining thickness of circlip -1-

Available circlips - Thickness of circlips in mm
3.035 3.080 3.125
– First try to fit thickest circlip in groove in gearbox housing.
• The circlip should fit without sticking.
• The circlip must be seated in the bottom of the groove.
– If the circlip cannot be fitted, try to insert the next thinnest cir‐
clip; if necessary use the thinnest circlip
– Renew ATF filter ⇒ multitronic 0AW, front-wheel drive; Rep.
gr. 37 ; ATF circuit; Removing and installing ATF filter .
8.
1.9 Removing and installing input shaft cov‐

er
♦ Oil seal extractor - T40014-

♦ Ice spray
♦ Protective gloves
♦ Safety goggles
Removing
• Input shaft is removed ⇒ page 24
– Pull out oil pipe -arrow- upwards so as to avoid damage.
– Check all 8 bolts -arrows- of thrust piece -T40099- .

• Bolts should have been screwed in flush to 25 Nm ⇒ Assembly
instructions for thrust piece -T40099- .

– Place input shaft in thrust piece - T40099- .

– Screw oil seal extractor - T40014- into oil seal by hand until
tool grips securely in seal. Then tighten tool using an open-
end spanner.
– Screwing in the rear bolt -arrow- will allow you to pull the oil
seal out a little.
– Then re-apply the open-ended wrench so that the oil seal ex‐
tractor - T40014- firmly engages in the oil seal again and screw
in the bolt to further extract the seal.
– Repeat procedure until oil seal is pulled out all the way.
– Remove circlip -1- securing input shaft cover.

– Measure and note down thickness of circlip once removed.
Note
When installing ball bearing, replace circlip with a new one of the
same thickness.
– Clean contact surface for input shaft cover.
WARNING
Risk of injury from burns.

♦ Wear protective gloves and safety goggles!
– Cool inside of hollow shaft -1- at seat -arrow 2- of input shaft

ball bearing -2-, e.g. by applying ice spray through opening
-arrow 1- left by removing oil pipe.
Note
♦ The illustration shows a sectional view of the input shaft.

♦ The input shaft has to be cooled so that cover and ball bearing
can be pressed off more easily without damage.

– Clean surface of thrust piece -T40099- .

– Place input shaft on thrust piece.
• Contact surface of input shaft cover should be seated flush.
• There must be no metal particles or dirt between contact sur‐
face of input shaft cover and surface of thrust piece -T40099- .
– In addition, cool the input shaft from the outside -arrow- e.g.
with ice spray.
Note
The input shaft has to be cooled so that cover and ball bearing
can be pressed off more easily without damage.
– Place input shaft together with thrust piece - T40099- on thrust

plate of hydraulic press.
Note
The thrust piece - T40099- should rest as firmly as possible on

the hydraulic press.
– Press input shaft out of cover with hydraulic press while hold‐
ing input shaft from below.
– Set down input shaft on assembly tool -T10219/1- .

Installing
– Renew ball bearing for input shaft ⇒ page 35 .
– Place input shaft cover on input shaft and press on as far as
possible by hand.
– Place input shaft -B- on thrust plate - VW 401- .
Caution
Take care to keep the input shaft straight and aligned centrally
when positioning it beneath the press tool of the hydraulic
press, as the input shaft may otherwise tilt to one side when
pressure is applied to the cover.
– Use hydraulic press and tube - VW 416 B- to press input shaft

cover -A- all the way home on the input shaft.
– Replace circlip -A- with a new one of the same thickness when
installing.
• The circlip must be seated in the bottom of the groove.
– Assess wear on gearbox components ⇒ page 60 .

– Renew O-ring -2- on oil pipe.

• The oil pipe is pressed into the input shaft with the O-ring -2-
first.
• You should feel oil pipe engage. Rotor vanes -arrow A- on oil
pipe should be completely inside input shaft.
– Press oil pipe -arrow- down into input shaft as far as stop.
• With oil pipe fully inserted, distance -a- from end of oil pipe to
input shaft should be approx. 11.5 mm.
Note
♦ If the distance is less, the oil pipe may be damaged (the end
could have broken off if the oil pipe was pushed in too far).
♦ If the distance is larger, the oil pipe is not pushed in far enough.
Caution
pipe -arrow-.
1.10 Renewing ball bearing for input shaft

♦ Thrust plate - VW 401-

♦ Tube - VW 416 B-
♦ Tube - 2010-
Procedure
• Cover for input shaft is removed ⇒ page 30 .
– Remove circlip -1-.
– Measure and note down thickness of circlip once removed.
Note
When installing ball bearing, replace circlip with a new one of the
same thickness.

– Position input shaft cover -1- on thrust piece - T40099- and

place beneath hydraulic press.
– Press ball bearing for input shaft out of input shaft cover using
tube - VW 416 B- .
Note
♦ In some cases, the input shaft ball bearing can be pressed out
by hand without using the hydraulic press.
♦ The input shaft ball bearing must be renewed.
Caution
Check the input shaft cover ⇒ page 62 .
– If contact surface or cover is damaged, renew input shaft cov‐

er.
Note
New input shaft covers are already fitted with a new ball bearing.
– If contact surface and cover are not damaged, renew input

shaft ball bearing -2-.
– Clean ball bearing seat in cover.
Caution
• Ball bearing cage must face downwards into input shaft

cover. Open side of ball bearing must face upwards, i.e.
balls in bearing must be visible on insertion.
– Fit ball bearing so that it is seated flush and then press in by

hand straight and as far as possible.

Caution
Risk of damage to input shaft cover

♦ To ensure that the input shaft cover rests flat on thrust
plate - VW 401- make sure that the cast lug -arrow- is lo‐
cated in an aperture in the thrust plate.
– Place input shaft cover on thrust plate - VW 401- .

– Press input shaft ball bearing in as far as stop using tube -
2010- .
– Replace circlip -1- with a new one of the same thickness when
installing.
– Check correct positioning of the circlip. If necessary, press in
the ball bearing further or use the next thinnest circlip.

2 Clutch
⇒ “2.1 Exploded view - reverse gear clutch”, page 39
⇒ “2.2 Exploded view - input shaft with friction plates”,
page 40
⇒ “2.3 Removing and installing reverse gear clutch and deter‐
mining shim thicknesses”, page 40
⇒ “2.4 Dismantling and assembling input shaft”, page 47
⇒ “2.5 Adjusting input shaft and checking clearance”, page 54
⇒ “2.6 Assessing wear on input shaft”, page 60
2.1 Exploded view - reverse gear clutch
1 - Corrugated washer
❑ Renew
2 - Bottom shim
“E1” ⇒ page 42
❑ The thickness of the bot‐
tom shim “E1” must be
at least 2.15 mm
❑ Renew
3 - Friction plate
❑ 6x
❑ Renew
4 - Top shim
“E2” ⇒ page 42
❑ Renew
5 - Outer plate
❑ 5x
❑ Renew
2. Clutch 39
2.2 Exploded view - input shaft with friction plates
1 - Bottom shim
⇒ page 54
❑ Renew
2 - Outer plate
❑ 6x
❑ Renew
3 - Friction plate
❑ 7x
❑ Renew
4 - Top shim
⇒ page 54
❑ Renew
5 - Corrugated washer
6 - Pressure plate
❑ Wear assessment pro‐
cedure ⇒ page 60
7 - Piston
❑ Wear assessment pro‐
cedure ⇒ page 60
8 - Cover
❑ For input shaft
❑ After removing cover,
renew ball bearing for
input shaft ⇒ page 35
9 - Circlip
❑ For input shaft cover
❑ Replace with one of
same thickness
10 - Oil seal
❑ For input shaft
❑ Renewing ⇒ page 70
11 - Input shaft
❑ Wear assessment procedure ⇒ page 60
12 - O-ring
❑ Renew
13 - Oil pipe
❑ Wear assessment procedure ⇒ page 60
2.3 Removing and installing reverse gear

clutch and determining shim thickness‐
es

♦ Digital depth gauge - VAS 6087-
♦ Digital caliper, 150 mm - VAS 6335-

♦ 2x ruler - T40100-
♦ Clean, flat measurement surface, e.g. compressor tool -

T10285-
2. Clutch 41
Removing reverse gear clutch
Note

• Gearbox must be removed and secured in a vertical position

on engine and gearbox support ⇒ page 15 .
– Remove input shaft ⇒ page 24 .
– Take reverse gear clutch with corrugated washers -1 ... 5- out
of gearbox.
– Measure top shim -4- and bottom shim -2- and note down val‐
ues.
Note
The purpose of noting down the values for the originally fitted top
shim -4- and bottom shim -2- is to provide a check for the newly
determined shims as described below. If there is a large differ‐
ence between the values for the old shims and the new shims,
the measurement must be repeated.
Adjusting reverse gear clutch by determining shims:
Note
The purpose of the following measurements is to determine the

thickness of the top shim -4- and bottom shim -2- for setting the
reverse gear clutch.
• To ensure accuracy, the surfaces of all tools and components

must be absolutely clean when performing the following meas‐
urements.
1. Calculating dimension -B-; measurement from contact surface

of input shaft cover to contact surface of corrugated washer:
– Clean contact surfaces and sealing surfaces on gearbox hous‐
ing. Completely remove any remaining sealing material.
– Use digital depth gauge -VAS 6087- to measure from contact
surface of input shaft cover to contact surface of corrugated
washer in gearbox housing.
– Note down dimension “B1”.
– Repeat measurement at two other points on the circumference
and note down dimensions “B2” and “B3”.
– Calculate mean value -B- from the 3 measured values and
note down.
Mean value: B1 + B2 + B33 = dimension -B-
– Note down dimension -B-.
Example:
29.0 mm + 28.9 mm + 29.0 mm3 = 28.97 mm
In this example, dimension -B- = 28.97 mm.

2. Calculating dimension -A-; measurement of compressed clutch

pack:
• The corrugated washer -2- is fitted beneath the clutch pack for
the measurement.
• Use a clean, flat measurement surface -1- as a base. Com‐
pressor tool - T10285- is used in the following description.
– First place corrugated washer -A- on measurement surface

-1-.
– Then alternately place friction plates -C- (6x) and outer plates
-B- (5x) one at a time on corrugated washer (all aligned in the
same position).
– Make sure that all plates are accurately aligned one on top of
the other.
– Place two rulers -T40100- on top of clutch pack.
Note
The weight of the rulers -T40100- presses the air out from be‐
tween the plates and exerts the specified 2.5 kg load on the
corrugated washer so it is compressed.
– Use digital depth gauge -VAS 6087- to measure down to work‐

ing surface -1- and note down measured value “a1”.
• When taking measurements, the digital depth gauge -VAS
6087- must make flush contact with both rulers -T40100- .
– Repeat measurement on opposite side of clutch pack and note
down measured value “a2”.
– Move the two rulers -T40100- 90° from their first position.
– Repeat measurements and note down measured values “a3”
and “a4”.
– Calculate mean value -a- from the 4 measured values and
note down.
Mean value: a1 + a2 + a3 + a44 = -a-
2. Clutch 43
Calculating dimension -A-:

– Measure and note down thickness -b- of rulers -T40100- .
The height of the compressed clutch pack is -a- – -b- = dimen‐
sion -A-.
– Note down dimension -A-.
Example:
Mean value measured with depth gauge 35.45 mm
35.45 mm + 35.46 mm + 35.42 mm + 35.47 mm4 = -a-
– Thickness -b- of rulers -T40100- – 7.47 mm
= Dimension -A- of compressed clutch pack = 27.98 mm
3. Calculating dimension -C-; measurement from contact surface

of input shaft cover to piston of reverse gear clutch:
– Place a clean outer plate -1- on input shaft (removed from

gearbox).
Note
The outer plate -1- is placed on the piston of the reverse gear
clutch in order to obtain a correct measurement to the highest
point of the piston. The thickness -d- of the outer plate -1- is sub‐
sequently added when calculating the height of the piston.

– Use digital depth gauge -VAS 6087- to measure from contact

surface -2- of input shaft cover to previously fitted outer plate
-1- and note down measured value “D1”.
– Repeat measurement at another point on the circumference
and note down measured value “D2”.
– Calculate mean value -D- from the 2 measured values and
note down.
Mean value: D1 + D22 = -D-
– Remove previously fitted outer plate from input shaft and

measure thickness -d- using digital caliper, 150 mm - VAS
6335- .
Calculating dimension -C-:

Calculate dimension -C- from contact surface of input shaft cover
to piston of reverse gear clutch:
-D- + -d- = dimension -C-
– Note down dimension -C-.
Example:
Mean value -D- = 4.51 mm + 4.49 mm2 = 4.50 mm
+ Thickness -d- of outer plate -1- fitted before measurement + 1.95 mm
= Dimension -C- from contact surface of input shaft cover to piston of reverse gear clutch = 6.45 mm
4. Determining thickness of the two shims “Etot.”:

– Calculate thickness of shims according to the following for‐
mula from noted dimensions “A”, “B” and “C” and a constant
value of 3.0 mm for clearance:
“B” + “C” – “A” – 3.0 mm = “Etot.”
2. Clutch 45
– Determine bottom shim “E1” and top shim “E2” from table
⇒ page 46 .
Thickness of both Thickness of bottom Thickness of top
shims “Etot.” shim “E1” shim “E2”
in mm in mm in mm
3.916 … 4.165 1.90 2.15
4.166 … 4.435 2.15 2.15
4.436 … 4.675 1.90 2.65
4.676 … 4.925 1.90 2.90
4.926 …5.165 1.90 3.15
5.166 … 5.425 2.15 3.15
5.426 … 5.675 2.65 2.90
5.676 … 5.925 2.65 3.15
5.926 … 6.175 2.90 3.15
6.176 … 6.400 3.15 3.15
Note
Select correct shims from ⇒ Electronic parts catalogue .
Example:
The example is based on the following values:
♦ Dimension “A” = 27.98 mm
♦ Dimension “B” = 28.97 mm
♦ Dimension “C” = 6.45 mm.
♦ Constant value for clearance = 3.0 mm
“B” + “C” – “A” – 3.0 mm = “Etot.”
28.97 mm + 6.45 mm – 27.98 mm – 3.0 mm = 4.44 mm
“Etot.” = 4.44 mm
– Thickness of bottom shim “E1” from table: 1.90 mm
– Thickness of top shim “E2” from table: 2.65 mm

Installing reverse gear clutch
Note
As an additional check, compare the thickness of the new shims

as determined above with the thickness of the old shims as meas‐
ured at the beginning of the procedure ⇒ page 42 . If there is a
large difference between the values for the old shims and the new
shims, the measurement must be repeated.
• Thoroughly clean all components prior to installation.

– Insert corrugated washer -6- in guides -1- (3x) in gearbox.
– Insert bottom shim “E1” -item 2- of calculated thickness in
guides in gearbox.
– Then alternately fit friction plates -3- and outer plates -5- in
guides in gearbox (all aligned in the same position).
– Finally insert top shim “E2” -item 4- of calculated thickness in
guides in gearbox.
– Align plates of reverse gear clutch using a straight-edge or

similar.
• The teeth must be set exactly in line.
– Install input shaft ⇒ page 24 .
2.4 Dismantling and assembling input shaft
2. Clutch 47
Special tools and workshop

equipment required
♦ Assembly tool -T10219/1-
♦ Tube - 2010-
♦ Tube - VW 416 B-


♦ 2x ruler - T40100-
♦ Gauge block - T40101-
♦ Feeler gauges - T40102-
♦ Digital depth gauge - VAS
6087-
♦ Protective gloves
♦ Ice spray
Dismantling input shaft

• Gearbox removed
Note

– Remove input shaft ⇒ page 24 .

– Remove cover from input shaft ⇒ page 30 .
2. Clutch 49

– Use two screwdrivers -arrows- to carefully lift pressure plate
with piston.
To prevent damage:
Caution
• The inner contact and sealing surfaces -arrow A- of the

pressure plate and the piston -arrow C- must not be al‐
lowed to make contact with the shaft on removal/installa‐
tion.
• The contact and sealing surfaces must not exhibit the
slightest signs of damage such as scratches or scoring
caused by dismantling/assembly.
• In the event of damage, the pressure plate or piston must
be renewed.
– Carefully guide the pressure plate -1- with piston -2- upwards
over the shaft -3-.
• When doing so, the inner contact surfaces of the pressure
plate -1- and of the piston -2- must not make contact with the
shaft.

Removing clutch pack

– Remove corrugated washer -5- (washer must be re-used).
– Take top shim -4- out of input shaft cylinder -A-.
– Measure thickness of shim -4- and note down value.
– Take all friction plates -2- and outer plates -3- out of input shaft
cylinder -A-.
– Remove bottom shim -1- from input shaft cylinder -A-.
– Measure thickness of shim -1- and note down value.
Caution
• Always renew old used shims, outer plates and friction

plates. They must not be re-installed otherwise proper op‐
eration of the input shaft cannot be assured (due to the
worn surface).
• The corrugated washer must be re-used.
Assembling input shaft
Caution
Assess wear on gearbox components prior to assembly

⇒ page 60 .
– Renew ball bearing for input shaft ⇒ page 35 .

– Adjust input shaft and determine clearance ⇒ page 54 .
Caution
• Always renew old used shims, outer plates and friction

plates. They must not be re-installed otherwise proper op‐
eration of the input shaft cannot be assured (due to the
worn surface).
• The corrugated washer must be re-used.
2. Clutch 51
– Insert chosen bottom shim -1- in input shaft cylinder -A-.

– Now build up the clutch pack by alternately inserting one fric‐
tion plate -2- followed by one outer plate -3-, ensuring that they
are aligned together.
Alignment of friction plates:
Caution
• The friction plates must be aligned together when instal‐

led, i.e. the areas with no external teeth -arrows- must be
stacked on top of each other. This is the only way to en‐
sure correct adjustment. If necessary, mark the input shaft
cylinder to ensure proper alignment on installation.
– Insert chosen top shim -4- in input shaft cylinder -A-.

– Finally insert corrugated washer -5-.

– Press home piston -1- in pressure plate -2-.
Caution
• The inner contact and sealing surfaces -arrow A- of the

pressure plate and the piston -arrow C- must not be al‐
lowed to make contact with the shaft on removal/installa‐
tion.
• The contact and sealing surfaces must not exhibit the
slightest signs of damage such as scratches or scoring
caused by dismantling/assembly.
• In the event of damage, the pressure plate or piston must
be renewed.
– Carefully guide pressure plate -1- with piston -2- downwards

over shaft -3-.
• When doing so, the inner contact surfaces of the pressure
plate -1- and of the piston -2- must not make contact with the
shaft.
– Evenly press home the pressure plate with piston in the input
shaft.
2. Clutch 53
Checking clearance with feeler gauges - T40102-

– Insert the two feeler gauges -T40102- underneath the pres‐
sure plate -A-.
– Have a second mechanic use the tube - VW 416 B- to press
down the pressure plate -A- as far as it will go -arrow 1-.
– Move the two feeler gauges -T40102- back and forth in a circle
beneath the pressure plate in direction of -arrow-.
• Apply the two feeler gauges -T40102- on opposite sides.
• Take care to keep the feeler gauges -T40102- straight.
• The entire circular area must be checked.
• The two feeler gauges -T40102- must always move freely
without any resistance whatsoever.
If the feeler gauges -T40102- cannot be moved in direction of
-arrow- without becoming blocked:
– Repeat the input shaft adjustment procedure ⇒ page 54 .
Caution
It is essential to obtain a successful result when checking the

clearance with the feeler gauges -T40102- , as gearbox prob‐
lems will otherwise be encountered when driving off from a
standstill.
If the feeler gauges -T40102- move freely in direction of -arrow-:

– Fit input shaft cover ⇒ page 30 .
– Install input shaft ⇒ page 24 .
– Fit input shaft oil seal ⇒ page 70 .
8.
2.5 Adjusting input shaft and checking

clearance
Note

Measuring the clutch
Note
♦ This measurement determines the distance -K- on the clutch

from the top shim to the stop ring at the shaft (contact surface
of pressure plate).
♦ The corrugated washer -1- is fitted beneath the clutch pack for
the measurement.
• Thoroughly clean all components prior to installation.

– Insert new bottom shim -1- of same thickness as old shim in

cylinder of input shaft -A-.
– Then insert corrugated washer -2-.
Note
The corrugated washer is only fitted at the bottom for measure‐

ment. On assembly it is fitted at the top again.
– Now build up the clutch pack by alternately inserting one fric‐

tion plate -3- followed by one outer plate -4-, ensuring that they
are aligned together.
Alignment of friction plates:
Caution
• The friction plates must be aligned together when instal‐

led, i.e. the areas with no external teeth -arrows- must be
stacked on top of each other. This is the only way to en‐
sure correct adjustment. If necessary, mark the input shaft
cylinder to ensure proper alignment on installation.
2. Clutch 55
– Finally insert new upper shim -5- of same thickness as old

shim in input shaft.
Note
To ensure accuracy, the surfaces of all tools and components

must be absolutely clean when performing the following meas‐
urements.
– Place the four gauge blocks -T40101- on the top shim.
– Place a ruler -T40101- over the centre of each pair of gauge

blocks -T40100- .

– Use digital depth gauge -VAS 6087- to measure down to shim

and note down measured value -A-.
• When taking measurements, the digital depth gauge -VAS
6087- must make flush contact with both rulers -T40100- .
– Then use digital depth gauge -VAS 6087- to measure down to

contact ring on shaft (contact surface of pressure plate) and
note down measured value -B-.
– Subtract the two measured values “B – A” to obtain the dis‐

tance -K- of the clutch.
Calculation of distance -K- of clutch: “B – A = K”
Note
The corrugated washer -1- is fitted beneath the clutch pack for
the measurement.
– Repeat the measurement on the opposite side of the input

shaft and again determine the distance -K- of the clutch.
– Move the four gauge blocks -T40101- and the two rulers -
T40100- through 90° on the input shaft and repeat the meas‐
urements.
– Take the four values determined for the distance -K- of the
clutch and calculate the mean value MK.
Mean value: “(value 1 + value 2 + value 3 + value 4) : 4 = MK”
Measuring the pressure plate

– First check for damage and renew if necessary.
– Turn the pressure plate over and set it down on a flat, clean
surface.
– Place the two gauge blocks -T40101- on the cleaned contact
surface of the pressure plate.
• The gauge blocks -T40101- must make full contact with the
clean contact surface and not rest on the edge.
2. Clutch 57
– Place the rulers -T40100- over the centre of the gauge blocks
-T40101- .
– Use digital depth gauge -VAS 6087- to measure down to upper
contact surface and note down measured value -A-.

– Use digital depth gauge -VAS 6087- to measure down to lower

contact surface and note down measured value -B-.
– Subtract the two measured values “B – A” to obtain the dis‐
tance “D” of the two contact surfaces on the pressure plate.
Calculation of distance “D” on pressure plate: “B – A = D”
– Repeat the measurement at 2 further points on the pressure
plate, offset by 120° in each case.
– Calculate the mean value for the pressure plate MD from the
three measured values.
Mean value: “(value 1 + value 2 + value 3) : 3 = MD”
Determining the clearance
– Determine clearance using the following formula:
Mean value of pressure plate measurements “M D”
(value 1 + value 2 + value 3) : 3
– Mean value of clutch measurements “MK”
(value 1 + value 2 + value 3 + value 4) : 4
= Clearance
Clearance = “MD” – “MK”
• Clearance specification: 1.8 ± 0.2 mm.
If result does not match specification:
A - Measured value too low:
– Insert appropriately thinner shim. It may also be necessary to
renew the bottom shim.
– Check clearance again after inserting new shim ⇒ page 54 .
B - Measured value too high:
– Insert appropriately thicker shim. It may also be necessary to
renew the bottom shim.
– Check clearance again after inserting new shim ⇒ page 54 .
The following shims are available:
Available shims [thickness in mm]
1.90 2.15 2.65
2.90 3.15
Note
The clearance can be adjusted by means of the top and bottom

shims.
2. Clutch 59
If result matches specification:

– Take all shims, friction plates, outer plates and the corrugated
washer -5-, -4-, -3-, -2- and -1- out of input shaft cylinder -A-.
Caution
This step is necessary as the corrugated washer -2- is fitted

above the bottom shim -1- only when adjusting the input shaft.
When assembling the input shaft, the corrugated washer is fit‐
ted at the top.
– Assemble the input shaft ⇒ page 51 .
2.6 Assessing wear on input shaft
3 - Friction plates
6 - Pressure plate
❑ Checking for wear
⇒ page 61
7 - Piston
⇒ page 61
8 - Cover
❑ For input shaft
❑ Checking ⇒ page 62
10 - Ball bearing
❑ For input shaft
❑ Renew ball bearing if in‐
put shaft cover has been
removed
11 - Input shaft
❑ Checking contact and
sealing surfaces for
wear ⇒ page 61
❑ Checking for traces of
scoring by friction plates
⇒ page 62
13 - Oil pipe
⇒ page 62

Checking piston and pressure plate for wear

– Pull piston -1- out of pressure plate -2-.
Checking pressure plate -2-
– Check contact/sealing surface -arrow A- of pressure plate for
wear.
– Check contact/sealing surface -arrow D- of pressure plate for
wear.
• If the contact/sealing surface -arrow A- is scored or scratched,
the pressure plate -2- must be renewed.
• If the contact/sealing surface -arrow D- is scored or scratched,
the pressure plate -2- and the piston -1- must be renewed.
Checking piston -1-
– Check oil seal -arrow B- on outer circumference of piston -1-
for damage.
– Check contact surface -arrow C- on inner circumference of
piston -1- on shaft.
• If the oil seal -arrow B- is damaged or the contact surface
-arrow C- of the piston is scored or scratched or of uneven
thickness due to wear, the piston -1- must be renewed.
Checking contact and sealing surfaces of input shaft for wear

– Check contact/sealing surface -arrow A- of input shaft for
wear.
Note
♦ The oil seal in the input shaft cover provides a seal on this
sealing surface -arrow A-.
♦ Slight scoring caused by the oil seal is normal.
– Check contact surface -arrow B- of ball bearing for input shaft

in input shaft cover for wear.
– Check oil seal -arrow C- on input shaft for damage.
• If oil seal -arrow C- is damaged or contact surfaces
-arrow B- or -arrow A- on input shaft are severely scored, the
entire input shaft must be renewed.
2. Clutch 61
Checking for scoring caused by friction plates on inner circum‐

ference of input shaft cylinder
– Check inner circumference of input shaft cylinder for scoring
caused by friction plates -arrows-.
• If scoring by friction plates -arrows- is found on inner circum‐
ference of input shaft cylinder, the entire input shaft must be
renewed.
Assessing wear on oil pipe

– Check oil seal -1- on oil pipe for damage.
• There should be a gap on the seal -arrow B-.
• If gap -arrow B- is completely closed, oil pipe must be re‐
newed.
– Check contact surfaces -arrows- and rotor vanes -arrow A- on
oil pipe for wear and damage.
• Oil pipe must be renewed if oil seal -1- or rotor vanes
-arrow A- are damaged or if contact surfaces -arrow- are se‐
verely scored.
• O-ring -2- must be renewed.
– Check contact surface of oil pipe in suction-jet pump.
Checking input shaft cover

– Check the contact surface of the cover -arrow- and the cover
itself for damage.
• The contact surface must not exhibit any signs of damage.
• The input shaft cover must not be broken or cracked.
– If contact surface or cover is damaged, renew input shaft cov‐
er.

39 – Final drive - differential

1 Final drive
⇒ “1.1 Exploded view - final drive”, page 63
1.1 Exploded view - final drive
Note

1 - Oil seal
❑ For input shaft
for input shaft”,
page 70
2 - Oil seal
❑ For flange shaft (left-
side)
(left-side)”, page 66
3 - Differential
4 - Bolt
❑ Renew
❑ Tightening torque and
sequence ⇒ page 65
5 - Oil seal
❑ For flange shaft (right-
side)
(right-side)”, page 69
6 - Flange shaft (right-side)
❑ Removing and installing
⇒ multitronic 0AW,
front-wheel drive; Rep.
gr. 39 ; Differential; Re‐
moving and installing
flange shaft (right-side)
stalling flange shaft
(right-side)”, page 78
7 - Circlip
❑ Renew
8 - Filler and inspection plug
❑ For gear oil in front final drive
❑ Renew
❑ 30 Nm
9 - Cover
❑ For front final drive
1. Final drive 63
❑ Pay attention to dowel sleeves

❑ Removing and installing ⇒ page 66
❑ Pre-fill if cover for front final drive has been removed ⇒ multitronic 0AW front-wheel drive; Rep. gr. 39 ;
Gear oil; Draining and filling gear oil
10 - O-ring
❑ On cover for front final drive
❑ Renew
11 - Bolt
❑ 10 Nm
12 - Gearbox selector lever
13 - Oil seal
❑ For selector shaft
❑ ⇒ “2.4 Renewing selector shaft oil seal”, page 71
14 - Gearbox
15 - Flange shaft (left-side)
❑ ⇒ “3.1 Removing and installing flange shaft (left-side)”, page 75
16 - Bolt
❑ Renew
❑ 10 Nm +90°
17 - Mounting bracket
❑ For flange shaft (left-side)
❑ Secured to flange shaft (left-side) together with ball bearing -item 17- by retaining clip -18-.
❑ If wear is visible on mounting bracket, check preload of ball bearing for flange shaft (left-side)
⇒ page 79
❑ Removing and installing ⇒ page 85
18 - Ball bearing
❑ For flange shaft (left-side)
❑ Checking preload of ball bearing for flange shaft (left-side) ⇒ page 79
❑ ⇒ “3.4 Renewing mounting bracket and ball bearing for flange shaft (left-side)”, page 85
19 - Retaining clip
❑ Renew
20 - Housing cover
❑ With gasket
21 - Bolt
❑ Renew
❑ 5 Nm +90°
22 - Dual-mass flywheel
❑ ⇒ “1.4 Removing and installing dual-mass flywheel”, page 19
64 Rep. gr.39 - Final drive - differential

Cover for front final drive - tightening torque and sequence
Note
Renew bolts which are tightened by turning through a specified

angle.
– Tighten bolts in 3 stages in the sequence shown:

Stage Bolts Tightening torque/tightening angle
1. -1 … 10- 3 Nm
2. -1 … 10- 20 Nm
3. -1 … 10- Turn 90° further
1. Final drive 65
2 Oil seals
⇒ “2.1 Renewing oil seal (left-side)”, page 66
⇒ “2.2 Renewing oil seal (right-side)”, page 69
⇒ “2.3 Renewing oil seal for input shaft”, page 70
⇒ “2.4 Renewing selector shaft oil seal”, page 71
2.1 Renewing oil seal (left-side)


Procedure
low gearbox.
– Remove flange shaft (right-side) ⇒ page 78 .
– Remove bolts -arrows- in diagonal sequence.
– Carefully detach cover for front final drive (gear oil will drain
off).
Caution
Risk of damage to the differential.

♦ Detach differential slowly and carefully from gearbox
housing. The differential may otherwise fall out of the
gearbox.
♦ A differential which has fallen to the ground can no longer
be installed. Renew gearbox if differential has fallen to the
ground.
♦ Make sure that the tapered roller bearing races and shims
of the differential do not fall out of the gearbox housing and
the differential.
♦ Tapered roller bearing races and shims cannot be re-al‐
located to their original positions by the workshop if they
have dropped out.
– Carefully remove differential -arrow- and set it down on a soft

surface.
– Remove flange shaft (left-side) ⇒ page 75 .
Caution
Risk of damage to fitting surface in gearbox housing.

♦ Apply screwdriver with care.
– Press out oil seal from rear side using a screwdriver.
2. Oil seals 67
– Lightly oil outer circumference of new oil seal and slide onto
thrust piece - T40164- .
• Open side of oil seal faces towards thrust piece - T40164- .
– Drive in oil seal for flange shaft (left-side) as far as stop using
thrust piece - T40164- ; keep seal straight when installing.
ing grease - G 052 128 A1- .
– Fit differential.
– Renew O-ring -A- on cover for front final drive and lubricate
lightly with gear oil.

– Install cover for front final drive with new O-ring and tighten
bolts to specified torque ⇒ page 65 .
– Install flange shaft (right-side) ⇒ page 78 .
– Before installing gearbox, front final drive must be pre-filled
with gear oil ⇒ multitronic 0AW, front-wheel drive; Rep. gr.
39 ; Gear oil; Draining and filling gear oil .
Caution

♦ Different types of gear oil are available for the “multitronic
0AW” gearbox.
♦ Use only the correct type of gear oil, as assigned to the
gearbox code letters.
♦ The gear oils must NOT be mixed, even in small quanti‐
ties. This would result in leaks at the oil seals. Select
correct gear oil for vehicle according to gearbox code let‐
ters ⇒ Electronic parts catalogue . Only the gear oil
available as a replacement part for the “multitronic 0AW”
may be used in the front final drive.
♦ The filler plug must always be renewed after checking the
oil level. Always select correct version according to gear‐
box code letters in ⇒ Electronic parts catalogue . To
prevent leaks on the gearbox, please check the new filler
plug by comparing it with the old one.
♦ The gear oil must NOT be mixed with other types of gear
oil, even in small quantities. This would cause leakage on
the gearbox.
– After installing gearbox, check gear oil level in front final drive
and correct as necessary ⇒ multitronic 0AW, front-wheel
drive; Rep. gr. 39 ; Gear oil; Checking gear oil level .
2.2 Renewing oil seal (right-side)

♦ Lever
2. Oil seals 69
Procedure
– Remove flange shaft (right-side) ⇒ page 78 .
– Lever out oil seal for flange shaft -arrow-.
– Lightly oil outer circumference of new oil seal.
– Drive in oil seal for flange shaft (right-side) as far as stop using
thrust piece - T40163- ; keep seal straight when installing.
ing grease - G 052 128 A1- .
– Install flange shaft (right-side) ⇒ page 78 .
2.3 Renewing oil seal for input shaft

♦ If ATF emerges at underside of gearbox bell housing, oil seal
for input shaft may be leaking.
♦ If leaking, the input shaft oil seal must be renewed.

Procedure
• Gearbox removed
Note

– Remove dual-mass flywheel ⇒ page 19 .

– Screw oil seal extractor - T40014- into oil seal by hand until
tool grips securely in seal. Then tighten tool using an open-
end spanner.
Note
The illustration shows a different gearbox.
– Screwing in the rear bolt of the oil seal extractor will allow you
to pull the oil seal out a little.
– Then tighten again using open-end spanner so that oil seal
extractor - T40014- once more engages securely in oil seal.
Screw in the rear bolt of the extractor once more to pull the oil
seal out a little further.
– Repeat procedure until oil seal is pulled out all the way.
• The input shaft must be installed in the gearbox when installing
the oil seal.
– Lubricate new oil seal -A- with ATF.

– Push oil seal onto input shaft (do not touch splines on shaft).
• Installation position: open side of oil seal points towards gear‐
box
Note
♦ Oil seal can be damaged if it touches splines on input shaft.

♦ Push oil seal as far as possible into cover to ensure that it
remains straight when driving in.
– Use thrust piece - T40167- to drive home oil seal (take care to
keep oil seal straight).
– Install dual-mass flywheel ⇒ page 19 .
– Check and correct ATF level after installing gearbox ⇒ multi‐
tronic 0AW, front-wheel drive; Rep. gr. 37 ; ATF; Checking
ATF level .
2.4 Renewing selector shaft oil seal

2. Oil seals 71
♦ Tube - VW 418 A-
Procedure
– Mark position of gearbox selector lever -A- relative to selector
shaft with a waterproof pen.
Note
The marking is to ensure that installation is performed correctly.
– Remove bolt -B- completely and lift off gearbox selector lever
-A-.
Caution
Risk of damage to selector shaft (shown here from rear side

with hydraulic control unit removed).
♦ The selector shaft must not be pressed into or pulled out
of the gearbox.
♦ The shifting cam -1- on the selector shaft will break off if
an upward or downward force is applied to the selector
shaft.
♦ The gearbox must be renewed if the shifting cam is dam‐
aged.

– Screw nut - T40188/1- onto puller - T40188/2- .

– Slide puller - T40188/2- over selector shaft.
– At the same time, press puller - T40188/2- firmly into oil seal
-A- in direction of -arrow 1- and screw in -arrow 2-.
Note
♦ The nut - T40188/1- was screwed onto the puller - T40188/2-

so that greater hand pressure can be applied in the direction
of -arrow 1-.
♦ The puller - T40188/2- cuts into the oil seal -A- when turned.
♦ Ensure that sealing surfaces on gearbox and selector shaft
are not damaged.
• Puller - T40188/2- must be seated very firmly in the oil seal. If

necessary, press in and turn puller - T40188/2- repeatedly.
– Set up cross member - T40188- and use screw feet at side to

align horizontally.
• Cross member - T40188- must be aligned so that nut -
T40188/1- can make flat contact.
• Distance -X- (approx. 8 mm) between lower edge of cross
member and puller - T40188/2- must be maintained. If neces‐
sary, insert washers as spacers between gearbox and screw
feet.
Note
The specified distance must be maintained so that the oil seal can
be pulled up towards the cross member. The puller - T40188/2-
will be damaged if it makes contact with the cross member before
the oil seal has been removed completely.
– Screw on nut - T40188/1- and pull out oil seal for selector shaft
-A-.
– Clean opening and vacuum out swarf.
– Lightly lubricate outer circumference and sealing lip of new oil

seal with ATF.
– Slip new oil seal over selector shaft and press in.
– Use tube - VW 418 A- to drive home oil seal.
2. Oil seals 73
– Fit gearbox selector lever -A- onto selector shaft in line with
marking and tighten bolt -B-.
Tightening torque for bolt

3 Differential
⇒ “3.1 Removing and installing flange shaft (left-side)”,
page 75
⇒ “3.2 Removing and installing flange shaft (right-side)”,
page 78
⇒ “3.3 Preload of ball bearing for flange shaft (left-side)”,
page 79
⇒ “3.4 Renewing mounting bracket and ball bearing for flange
shaft (left-side)”, page 85
3.1 Removing and installing flange shaft

(left-side)
Removing
– Tilt gearbox to rear on engine and gearbox support to prevent
gear oil from escaping.
– Unscrew bolts -arrows- on mounting bracket for flange shaft.
– Remove flange shaft (left-side) -2- from gearbox in direction

of -arrow A-.
Note
-Item 1- and -arrows 3, B- can be disregarded.
3. Differential 75
Note
♦ If the flange shaft (left-side) cannot be removed by hand, pull

it out carefully using multi-purpose tool - VW 771- .
♦ To do this, secure plate of puller - T10037- to flange shaft
-arrows- and attach plate to spindle of multi-purpose tool - VW
771- (nuts -A-).
– Remove dual-mass flywheel ⇒ page 19 .
Installing
• Tightening torque
– Thoroughly clean flange shaft (left-side), area of gearbox
housing leading to differential -arrow A-, and oil seal
-arrow B-.
Note
If oil seal for flange shaft (left-side) between differential and gear‐
box housing -arrow B- is damaged, it must be renewed
⇒ page 66 .
ing grease - G 052 128 A1- .
– Thoroughly clean flange shaft (left-side).
The following steps must be taken for vehicles listed below (up to
vehicle identification number shown):
Vehicle model Vehicle identifica‐ Place of manufac‐
tion number ture
Audi A4 2008 up to Germany, Neckar‐
WAUZZZ8K9BN03 sulm
4383
Audi A4 2008 up to Germany, Ingol‐
WAUZZZ8KXBA08 stadt
2742
Audi A5 Cabriolet up to Germany, Neckar‐
2008 WAUVGAFH3BN00 sulm
9542
Audi A5 Coupé up to Germany, Ingol‐
2008 WAUZZZ8T9BA90 stadt
2081
– Check preload of ball bearing for flange shaft (left-side) ac‐
cording to wear pattern on mounting bracket -arrow-
⇒ page 79 .
♦ Depending on wear pattern, optimise preload of ball bearing
for flange shaft (left-side) as required ⇒ page 80 .
♦ Depending on wear pattern, adjust preload of ball bearing for
flange shaft (left-side) as required ⇒ page 81 .

Continued for all vehicle models

– Install dual-mass flywheel ⇒ page 19 .
– Turn dual-mass flywheel -1- so that you can see opening to

differential -arrow 3-.
– Slide flange-shaft (left-side) -2- into gearbox in direction of
-arrow B- (keep end of shaft centred while guiding it into oil
seal on front final drive -arrow 3-).
Note
♦ The splines -2- on the flange shaft will damage the oil seal for
the flange shaft (left-side) between the final drive and the
gearbox housing if you do not keep the flange shaft centred.
♦ If the oil seal is damaged, it must be renewed.
♦ -Arrow A- can be disregarded.
– Tighten bolts -arrows-.

– After installing gearbox, fill up gear oil in front final drive and
check gear oil level ⇒ multitronic 0AW, front-wheel drive; Rep.
gr. 39 ; Gear oil; Checking gear oil level .
3. Differential 77
3.2 Removing and installing flange shaft

(right-side)
Note
The flange shaft (right-side) can also be removed and installed

with the gearbox in the vehicle ⇒ multitronic 0AW, front-wheel
drive; Rep. gr. 39 ; Differential; Removing and installing flange
shaft (right-side) .

♦ Drift - VW 295-
♦ Puller - T10037-

Removing
– Remove flange shaft (right-side); to do so, secure puller -
T10037- to gearbox housing -arrow-.
Installing

– Always renew circlip for flange shaft -A-.

– Clamp flange shaft in vice, using jaw protectors. Use new cir‐
clip -A- to press old circlip out of groove in flange shaft.
– Check flange shaft oil seal (right-side) -arrow- for damage and
renew if necessary ⇒ page 69 .
ing grease - G 052 128 A1- .
– Knock flange shaft in with drift - VW 295- .
– Fill up gear oil in front final drive and check gear oil level ⇒
multitronic 0AW, front-wheel drive; Rep. gr. 39 ; Gear oil;
Checking gear oil level .
3.3 Preload of ball bearing for flange shaft

(left-side)
⇒ “3.3.1 Checking preload of ball bearing for flange shaft (left-
side)”, page 79
⇒ “3.3.2 Optimising preload of ball bearing for flange shaft (left-
side)”, page 80
⇒ “3.3.3 Adjusting preload of ball bearing for flange shaft (left-
side)”, page 81
3.3.1 Checking preload of ball bearing for

flange shaft (left-side)
Check preload of ball bearing according to wear pattern on
mounting bracket -arrow-.
Note
♦ It is only necessary to check preload of ball bearing for flange

shaft (left-side) on certain vehicles; for list of vehicles see table
⇒ page 76 .
♦ This measure is not required on later vehicles because of a
design change.
⇒ page 75
3. Differential 79
Wear pattern “A”

• Slight impressions in vicinity of hole in mounting bracket
-arrows-.
• No trace of scoring or material worn down around circumfer‐
ence.
– Optimise preload of ball bearing for flange shaft (left-side)
⇒ page 80 .
Wear pattern “B”

• Scoring and possibly material worn down around circumfer‐
ence of hole in mounting bracket -arrow-.
– Adjust preload of bearing for flange shaft (left-side)
⇒ page 81 .
– Renew mounting bracket, ball bearing and circlip
⇒ page 85 .
3.3.2 Optimising preload of ball bearing for

Note
♦ It is only necessary to optimise preload of ball bearing for

flange shaft (left-side) on certain vehicles; for list of vehicles
see table ⇒ page 76 .
design change.
Procedure
• Flange shaft (left-side) must be removed ⇒ page 75 .

Requirements for optimising:

• Mounting bracket shows no trace of scoring or material worn
down around circumference.
• Slight impressions in vicinity of hole in mounting bracket
-arrows- are permissible.
• Mounting bracket with wear pattern “A” ⇒ page 80 (mounting

bracket has no traces of scoring or material worn down around
circumference).
• A shim is inserted in the bearing seat in the gearbox to optimise
the preload of the ball bearing.
– Before installing flange shaft , insert shim - 0B4 409 227-

-item 1- in bearing seat in gearbox to optimise preload of ball
bearing.
3.3.3 Adjusting preload of ball bearing for

Note
♦ It is only necessary to optimise preload of ball bearing for

flange shaft (left-side) on certain vehicles; for list of vehicles
see table ⇒ page 76 .
design change.
3. Differential 81
• Flange shaft (left-side) must be removed ⇒ page 75 .

• Mounting bracket with wear pattern “B” ⇒ page 80 (scoring and
possibly material worn down around circumference of hole).
• Mounting bracket and ball bearing must be renewed
⇒ page 85 .
Procedure
– Attach emery cloth (grain size 150) to sanding block and clean
coarse dirt and corrosion off contact surface -arrow-.
Note
The contact surface does not have to be sanded down to bare

metal; it is sufficient to remove coarse dirt and corrosion.
– Clean contact surface and bearing seat.
– Fit new ball bearing -arrow- for flange shaft (left-side) in bear‐
ing seat.
Continued procedure:
♦ If bearing protrudes slightly outside contact surface
⇒ page 83
♦ If bearing is below contact surface ⇒ page 84

Procedure if bearing protrudes outside contact surface

– Apply straight edge (500 mm) - VAS 6075- across bearing and
measure distance to contact surface on gearbox housing on
both sides using feeler gauge.
– Note down measured value.
– Re-apply straight edge at an angle of 90° across bearing and
measure distance to contact surface on gearbox housing on
Determining shim(s):
Note
The smallest of the 4 measured values is used to determine the

shim(s).
• Specification: bearing should protrude by 0.5 ... 0.8 mm

Smallest amount of bearing protrusion (0.1 mm in this ex‐
ample)
+ Thickness of shim(s), (thickness 0.3 mm)
= Bearing preload, (specification 0.5 ... 0.8 mm)
Example:
1 shim:
0.1 mm + 0.3 mm = 0.4 mm, “bearing preload insufficient”
2 shims:
0.1 mm + 0.3 mm + 0.3 mm = 0.7 mm “bearing preload in
specified range”
• Result: Inserting 2 shims of 0.3 mm thickness gives a bearing
preload of 0.7 mm (inside tolerance range of 0.5 … 0.8 mm)
3. Differential 83
Procedure if bearing is below contact surface
Note
Use only the method described here to measure the distance be‐
low the contact surface.
– Apply straight edge (500 mm) - VAS 6075- across contact

surface on gearbox housing and measure distance to bearing
on both sides using feeler gauge.
– Re-apply straight edge at an angle of 90° across contact sur‐
face on gearbox housing and measure distance to bearing on
Determining shim(s):
Note
♦ The largest of the 4 measured values is used to determine the

shim(s).
♦ The measured distance below the contact surface is taken as
a minus value (“–”) for the calculation.
• Specification: bearing should protrude by 0.5 ... 0.8 mm

– Largest distance below surface (–0.15 mm in this example)
+ Thickness of shim(s), (thickness 0.3 mm)
= Bearing preload (specification 0.5 ... 0.8 mm)
Example:
1 shim:
-0.15 mm + 0.3 mm = 0.15 mm, “bearing preload insufficient”
3 shims:
-0.15 mm + 0.3 mm + 0.3 mm + 0.3 mm = 0.75 mm, “bearing
preload in specified range”
• Result: Inserting 3 shims of 0.3 mm thickness gives a bearing
preload of 0.75 mm (inside tolerance range of 0.5 … 0.8 mm)
Continued for all vehicles:

– Renew mounting bracket, ball bearing and circlip
⇒ page 85 .
– Before installing flange shaft fit calculated number of shims
-0B4 409 227- -item 1- in bearing seat in gearbox.

3.4 Renewing mounting bracket and ball

bearing for flange shaft (left-side)
♦ Press tool - VW 412-
♦ Tube - VW 516-
3. Differential 85
– Remove flange shaft (left-side) ⇒ page 75 .

– Remove circlip -1- from flange shaft.
– Press ball bearing -A- off flange shaft.
– Fit new mounting bracket -1-.

• Installation position: side with lettering faces towards flange
for drive shaft.
– Fit new ball bearing -2-.

– With mounting bracket -B- installed, press on ball bearing

-A- as far as stop.
– Fit circlip -1- in annular groove on flange shaft.
3. Differential 87
4 Gearbox control system

⇒ “4.1 Removing and installing gearbox control unit”, page 88
⇒ “4.2 Removing and installing hydraulic control unit”,
page 90
4.1 Removing and installing gearbox control

unit
Removing
Note

– Remove end cover ⇒ page 21 .

– If fitted, detach displacer plate -A-.
– Unscrew bolts -arrows- and pull out automatic gearbox control

unit - J217- , taking care not to tilt it.
– Take twin-lip seal -B- off automatic gearbox control unit -
J217- .
Note
♦ Do not touch pins in connector -A- with bare hands.

♦ Take care that control unit senders are not damaged when
placing automatic gearbox control unit - J217- to side.
Installing
Note
Renew gaskets and O-rings.

– Clean senders -5 to 8- and connectors -1 to 3- to remove dirt

and metal particles if necessary.
– Clean selector shaft ⇒ page 23 .
– Before fitting automatic gearbox control unit -J217- , lubricate

new O-rings -A- on hydraulic control unit with ATF.
Note
-Arrows- can be disregarded.
– Bring automatic gearbox control unit - J217- into position, tak‐

ing care not to tilt it.
• Make sure that connectors on back of control unit mate cor‐
rectly with connectors -A-, -B- and -C- on hydraulic control unit.
– Tighten bolts -arrows-.
4. Gearbox control system 89

– If fitted, attach displacer plate -A- to automatic gearbox control

unit - J217- .
– Install end cover ⇒ page 21 .
– Fill up ATF and check and correct ATF level ⇒ multitronic
0AW, front-wheel drive; Rep. gr. 37 ; ATF; Checking ATF lev‐
el .
Caution
If the automatic gearbox control unit - J217- has been renewed,

you must carry out the following steps using a vehicle diag‐
nostic tester :
– Using the diagnostic tester in Guided Fault Finding mode, go

to Function/Component Selection and select the following
menu items:
♦ Drive system
♦ 0AW gearbox
♦ 01 - Self-diagnosis-compatible systems
♦ 02 - Gearbox electronics
♦ 02 - Gearbox electronics, Functions
♦ 02 - Replace control unit
4.2 Removing and installing hydraulic con‐

trol unit
Removing
Note

• End cover must be removed ⇒ page 21 .

• Automatic gearbox control unit - J217- must be removed
⇒ page 88 .

Caution
There is a risk of damage to the spring.

♦ Do not use sharp pliers or similar when inserting or re‐
moving spring.
♦ The detent for the selector shaft will no longer function
properly if the wire of the spring is damaged by incision or
kinking.
– Unhook spring -1- from lever for selector shaft detent -2- and
from selector shaft -3-.
– Swivel lever for selector shaft detent -1- to right -arrow- so that
retaining tab -A- is rotated out of slot on retaining plate -B-.
– Pull lever for selector shaft detent -1- downwards out of hole
in housing of hydraulic control unit. Pay attention to the roller
-2- when doing this.

– Remove bolts -arrows-.
Caution
Take care not to damage hydraulic control unit.

♦ NEVER suspend or lift the hydraulic control unit by the
long pump shaft on the rear side of the hydraulic control
unit!
♦ This would distort the vanes inside the vane pump and
damage the pump. There is also a risk of damaging the
bearing of the pump shaft.
– Carefully pull hydraulic control unit out towards rear and then
tilt it downwards so that the long pump shaft can be guided
out.
Note
Item -A- can be disregarded.
– Remove axial sealing elements -A- and -B- from gearbox.

Installing
Note
♦ Always renew contaminated or defective hydraulic control

units.
♦ Renew gaskets and O-rings.
– Renew axial sealing elements -A- (3x) and -B-.
• Installation position: axial sealing elements -A- must be inser‐

ted with sealing lips facing upwards, as shown in sectional
illustration.
• The coloured mark on the top edge must be visible.
– Coat axial sealing elements with ATF and insert in direction of
-arrow-.

– Push gearbox selector lever -2- all the way to the front in di‐
rection of -arrow- until shifting cam -1- is almost vertical (with
a slight inclination to the left).
– Push control piston -B- on reverse side of hydraulic control unit

outwards (to the right) until it clips into securing spring -A-.
– Tilt hydraulic control unit downwards and insert it into gearbox,
long pump shaft first.
Note
When fitting the hydraulic control unit, make sure the shifting cam
(-item 1- in illustration A38-10189 ⇒ page 93 ) engages in the
vacant groove -arrow- on the control piston -B-.
Caution
Take care not to damage hydraulic control unit.

♦ The hydraulic control unit will be damaged if the shifting
cam or the control piston are not in the correct position and
the bolts are already tightened to torque in the following
step.
– Screw in bolts -arrows- hand-tight.

Checking operation of control piston

– Move gearbox selector lever -A- forward and back several
times -arrow 1-.
• The control piston -B- should travel in and out accordingly
-arrow 2-.
If control piston fails to move this means that shifting cam has not
engaged in groove -arrow- of control piston on reverse side of
hydraulic control unit. In that case:
– Detach hydraulic control unit again.
Check for damage due to incorrect installation:

• It must be possible to slide control piston -B- smoothly to left
and right; if not, hydraulic control unit must be renewed.
• There must not be any damage to shifting cam -1- or selector
shaft due to incorrect installation.
– Insert hydraulic control unit again ⇒ page 93 .
If it is possible to move control piston as described:

– Tighten bolts -arrows- to torque.

Installing lever for selector shaft detent

– Push roller -2- onto lever for selector shaft detent -1- (with col‐
lar facing lever for selector shaft detent).
– Push lever for selector shaft detent -1- into hole in housing of
hydraulic control unit.
– Swivel lever for selector shaft detent -1- to left in opposite di‐
rection of -arrow- so that retaining tab -A- is rotated into slot
on retaining plate -B- and engages.
Caution
There is a risk of damage to the spring.

♦ Do not use sharp pliers or similar when inserting or re‐
moving spring.
♦ The detent for the selector shaft will no longer function
properly if the wire of the spring is damaged by incision or
kinking.
– Hook spring -1- into selector shaft -3- and lever for selector
shaft detent -2-.
Installation position of spring -1-:
• Bent end of spring must be hooked into selector shaft -3-.
• Round end of spring must be hooked into lever for selector
shaft detent -2-.
– Shift gearbox selector lever -A- forward and back as far as it

will go -arrow 1-.
Note
-Arrow 2- and item -B- can be disregarded.

• The detent plate -top arrow- moves to the left and right.
• As it moves, the roller -4- should be able to engage in the in‐
dividual notches one-by-one.
• Roller must be installed with the collar pointing downward, so
that it cannot be pulled off upwards.
– Install automatic gearbox control unit - J217- ⇒ page 88 .
Caution
If the hydraulic control unit has been renewed, carry out the
following steps using a vehicle diagnostic tester :
– Using the diagnostic tester in Guided Fault Finding mode, go

to Function/Component Selection and select the following
menu items:
♦ Drive system
♦ 0AW gearbox
♦ 01 - Self-diagnosis-compatible systems
♦ 02 - Gearbox electronics
♦ 02 - Gearbox electronics, Functions
♦ 02 - Replace hydraulic control unit

Servicing Multitronic 0AW

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Servicing multitronic 0AW

Service Department. Technical Information

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

1.1 General repair instructions

1.2 Contact corrosion

2 Rep. gr.00 - Technical data

1.3 Rules for cleanliness

1.4 Common faults

♦ Before commencing fault-finding, interrogate event memory of

1.1 Purging ATF

1.1.1 ATF purging procedure

Risk of damage to gearbox

– Fill up with ATF after installing gearbox

4 Rep. gr.37 - Controls, housing

5. ⇒ “1.1.2 Draining ATF (for ATF purging procedure)”,

Checking the ATF level completes the purging procedure.

1.1.2 Draining ATF (for ATF purging proce‐

♦ Used oil collection and extraction unit - V.A.G 1782-

Risk of damage to gearbox

• Engine not running.

– Remove rear noise insulation ⇒ General body repairs, exte‐

Risk of eye injury.

– Unscrew ATF inspection plug -A-.

♦ Please observe requirements for disposal.

6 Rep. gr.37 - Controls, housing

Gearbox with long, curved fluid level pipe:

Gearbox with short, straight fluid level pipe:

• O-ring -1- must be correctly fitted in groove on fluid level pipe.

– Continue ATF purging procedure ⇒ page 4 .

1.1.3 Filling up with ATF (for ATF purging pro‐

8 Rep. gr.37 - Controls, housing

♦ ATF charging device for CVT gearboxes - VAS 5162-

Risk of damage to gearbox

♦ The illustration on the reservoir of the ATF charging device for

Risk of damage to gearbox

– Remove O-ring -1- at connection -2- on ATF charging device

There is a risk of filling the gearbox incorrectly.

10 Rep. gr.37 - Controls, housing

– With O-ring removed, screw connection of ATF charging de‐

– Turn stopcock in direction of filling hose -lower arrow-. ATF

Rev engine up to approx. 2500 rpm immediately after starting.

1.1.4 Road test (for ATF purging procedure)

– Drive vehicle off lifting platform.

– Follow these instructions exactly and observe all safety pre‐

When road-testing the vehicle as described below, observe all

Press brake pedal if necessary.

– Press brake pedal and brake wheels to 0 km/h.

The complete test cycle has to be repeated five times to ensure

12 Rep. gr.37 - Controls, housing

Risk of damage to gearbox

♦ Workshop hoist - VAS 6100-

14 Rep. gr.37 - Controls, housing

3 Securing to engine and gearbox sup‐

♦ Engine and gearbox support - VAS 6095-

♦ Gearbox support - T40206- with -T40206/1-

♦ Bolt M8x30, nut, 2x washer

3. Securing to engine and gearbox support 15

16 Rep. gr.37 - Controls, housing

1.1 Exploded view - dual-mass flywheel