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8-speed automatic gearbox 0CM
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Edition 04.2013
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Repair Group
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00 - Technical data
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30 - Clutch
32 - Torque converter
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37 - Controls, housing
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38 - Gears, control
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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.
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1 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.2 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.3 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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1.4 ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
es, in part or in w 2
1.5 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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1.6 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.7 Contact corrosion! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
com
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4.1 Allocation of gearbox to engine, gear ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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4.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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32 - Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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1 Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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1.1 Assembly overview - torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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37 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.1 Assembly overview - selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3 Emergency release from position P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.5 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.6 Checking and adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.7 Removing and installing cable support bracket for selector lever cable . . . . . . . . . . . . . . . . 21
1.8 Removing and installing gearbox selector lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.1 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2 Renewing output shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.1 Removing and installing gearbox carrier/gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . 35
4 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.1 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5 ATF circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.1 Assembly overview - ATF circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.2 Removing and installing ATF cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.3 Removing and installing ATF lines, ATF cooler/thermostat . . . . . . . . . . . . . . . . . . . . . . . . 42
5.4 Removing and installing ATF lines, thermostat/gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.5 Removing and installing ATF filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.6 Cleaning ATF circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6 ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Contents i
Amarok 2011
8-speed automatic gearbox 0CM - Edition 04.2013
38 - Gears, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1 ATF system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.1 Assembly overview - sump/oil strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.2 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.3 Removing and installing hydraulic impulse oil storage with accumulator solenoid N485 . . 60
2 Mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.1 Removing and installing mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
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Amarok 2011
8-speed automatic gearbox 0CM - Edition 04.2013
00 Technical data
1 Repair instructions
(VRL005441; Edition 04.2013)
1.1 Tools, page 1
1.2 Gearbox, page 1
1.3 Gaskets and seals, page 2
1.4 ATF, page 2
1.5 Nuts and bolts, page 2
1.6 Electrical components, page 3
1.7 Contact corrosion!, page 3
1.1 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.
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1. Repair instructions 1
Amarok 2011
8-speed automatic gearbox 0CM - Edition 04.2013
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1.7 Contact corrosion!
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Contact corrosion can occur if non-approved fasteners are used
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Furthermore, rubber and plastic components as well as adhe
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If there are doubts about the suitability of fastening components,
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Damage resulting from contact corrosion is not covered by the
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1. Repair instructions 3
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2 Safety instructions
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2.1 Rules for safety when working on the
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To prevent personal injury and material damage to the vehicle,
observe the following:
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WARNING
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2. Safety instructions 5
Amarok 2011
8-speed automatic gearbox 0CM - Edition 04.2013
3 General notes
3.1 Rules for cleanliness when working on the gearbox, page
6
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4 Technical data
4.1 Allocation of gearbox to engine, gear ratios, page 7
4.2 Capacities, page 7
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6th gear 1.000 1.000 1.000 1.000
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7th gear 0.839 0.839 0.839 0.839
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Fill of ATF cooling system approx. 0.6 l
4. Technical data 7
Amarok 2011
8-speed automatic gearbox 0CM - Edition 04.2013
30 Clutch
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32 Torque converter
1 Torque converter
1.1 Assembly overview - torque converter, page 9
1.2 Proper handling of torque converter, page 9
1.3 Removing and installing torque converter oil seal,
page 10
1.4 Draining torque converter, page 11
1.5 Removing and installing torque converter, page 12
1 - Torque converter
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5 - O-ring
6 - Bolt
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1. Torque converter 9
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Removing
Apply oil seal extractor lever - VW 681- directly behind sealing
lip of seal to avoid damaging stop ring and lever out seal.
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Special tools and workshop equipment required
Used oil collection and extraction unit - V.A.G 1782-
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1. Torque converter 11
Amarok 2011
8-speed automatic gearbox 0CM - Edition 04.2013
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Remove gearbox page 25 .
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Installation dimension
The torque converter is correctly installed when the distance
-a- between the contact surfaces at the threaded holes of the
torque converter and the torque converter housing is at least
26.25 mm.
Ensure that the torque converter does not slide forwards
during the installation of the gearbox.
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13
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1. Torque converter
Amarok 2011
8-speed automatic gearbox 0CM - Edition 04.2013
37 Controls, housing
1 Selector mechanism
1.1 Assembly overview - selector lever handle, page 14
1.2 Checking selector mechanism, page 15
1.3 Emergency release from position P , page 16
1.4 Removing and installing selector lever handle,
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WARNING
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Before working on vehicle with engine running, move selector
lever into position P and apply handbrake.
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Cop py
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Prote AG.
1 - Clamp
Renew after each re
moval.
For attaching handle to
selector lever
2 - Handle with gaiter
Removing page 17
3 - Selector cover
Is removed together
with handle.
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1.2 Checking selector mechanism
itte
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WARNING
wit
, is n
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hole
spec
lever lock must not engage and block selector lever. Selector
ercia
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c
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solenoid for selector lever lock should only engage after about
t
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Selector lever in P position, ignition switched on: Cop py
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Do not operate brake pedal. p by
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Prote AG.
1. Selector mechanism 15
Amarok 2011
8-speed automatic gearbox 0CM - Edition 04.2013
pt
du
an
Note
itte
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erm
ab
ility
ot p
t to the co
nf
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m
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Removing
rrectness of i
Shift selector lever to position D.
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nf
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Prote AG.
1. Selector mechanism 17
Amarok 2011
8-speed automatic gearbox 0CM - Edition 04.2013
Note
ce
off. Never press button after removal, otherwise it will no longer
e
nl
pt
du
be possible to install handle.
an
itte
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Installing ot p
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spec
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Note
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c
in t
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can be restored. To do this, push installation guard fully in whilst
priv
c
button is pressed, release button and pull installation guard out
um
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Cop py
Push handle with new clamp fully onto selector lever until it ht. rig
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can be felt to engage. py by
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Press button in selector lever handle. Prote AG.
Note
Removing
Remove transfer box Power transmission; Rep. gr. 39 ;
Transfer box; Removing and installing transfer box .
Remove selector lever handle page 17 .
Pull securing clip -arrow- in -direction of arrow- off selector
lever cable -1- and out of guide.
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spec
Note
es, in part or in w
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Cop py
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by
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Prote AG.
1. Selector mechanism 19
Amarok 2011
8-speed automatic gearbox 0CM - Edition 04.2013
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
Checking
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Cop py
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du
using removal lever - 80-200- .
an
itte
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Move selector lever from P to D.
ility
ot p
Selector lever cable must move easily and smoothly.
wit
, is n
h re
hole
Move selector lever to P position.
spec
es, in part or in w
Move selector shaft lever on gearbox to position P. Locking
t to the co
lever must engage in parking lock wheel so that both front
wheels are blocked (cannot be turned together in same direc
tion).
rrectness of i
It must be possible to push selector lever cable onto selector
l purpos
shaft lever. Adjust selector lever cable if necessary.
Carefully press selector lever cable onto selector shaft lever.
nform
ercia
at
om
ion
Adjusting
c
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Cop py
Move selector shaft lever on gearbox to position P. Locking ht. rig
rig ht
lever must engage in parking lock wheel so that both front py by
co Vo
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wheels are blocked (cannot be turned together in same direc
by
cted agen
Prote
tion).
AG.
Loosen bolt -2- and press selector lever cable -1- onto selector
shaft lever.
Note
1. Selector mechanism 21
Amarok 2011
8-speed automatic gearbox 0CM - Edition 04.2013
Removing
Pull securing clip -arrow- in -direction of arrow- off selector
lever cable -1- and out of guide.
AG. Volkswagen AG d
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Press selector lever cable on ball head -arrow-
orise
off gearbox nte
eo
using removal lever - 80-200- . Then pull aut cable -1- in
h
ra
-direction of arrow- out of guide and lay
s to side.
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pt
du
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ab
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spec
es, in part or in w
t to the co
rrectness of i
at
om
ion
c
in t
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do
priv
cum
for
en
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t.
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Cop py
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rig ht
py by
co Vo
by lksw
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Prote AG.
Note
Lower gearbox.
pt
an
itte
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ab
ility
ot p
der frame1)
h re
hole
gearbox mounting1)
es, in part or in w
t to the co
1) Renew.
nform
ercia
at
tor lever
om
ion
c
in t
or
Removing
his
ate
do
priv
en
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t.
Remove mechatronic unit page 62 .
yi Co
Cop py
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Detach selector mechanism from gearbox page 19 .
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pyri by
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Prote AG.
1. Selector mechanism 23
Amarok 2011
8-speed automatic gearbox 0CM - Edition 04.2013
Note
Note
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
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m
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n in
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Cop py
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Prote AG.
2 Gearbox
2.1 Removing and installing gearbox, page 25
2.2 Renewing output shaft seal, page 33
AG. Volkswagen AG d
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ab
pe
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Gearbox 25
Amarok 2011
8-speed automatic gearbox 0CM - Edition 04.2013
AG. Volkswagen AG d
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es, in part or in w
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rrectness of i
Note
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Raise vehicle Maintenance ; Booklet 11 . C py
t. rig
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If fitted, remove engine/gearbox guard General body re
p by
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by c lksw
pairs, exterior; Rep. gr. 66 ; Engine/gearbox guard; Removing
Prote
cted AG.
agen
and installing engine/gearbox guard .
Remove starter Vehicle electrics; Rep. gr. 27 ; Starter; Re
moving and installing starter .
Remove front silencer Power unit; Rep. gr. 26 ; Exhaust
system; Exhaust pipes/silencers .
Remove front propshaft Transfer box and final drives; Rep.
gr. 39 ; Propshaft; Removing and installing front propshaft .
ce
e
nl
pt
du
an
Note
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
propshaft from flange -2-.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
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n in
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t.
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Cop py
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Prote AG.
Caution
2. Gearbox 27
Amarok 2011
8-speed automatic gearbox 0CM - Edition 04.2013
AG. Volkswagen AG d
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V gu
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Remove particulate
ss a filter bracket -1- from gearbox. To do this, c
unscrew bolts -arrows-.
ce
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nl
pt
du
an
itte
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erm
ab
Note
ility
ot p
wit
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
orm
m
atio
m
Note
o
n in
or c
thi
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sd
iva
que converter.
o
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rp
cu
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en
t.
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turn crankshaft by 120 to access the bolts one after another. t. Cop py
rig
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pyri by
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by c lksw
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Prote AG.
Note
Catch oil which runs out. Seal ATF lines and gearbox using clean
plugs from engine bung set - VAS 6122- .
AG. Volkswagen AG d
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Unscrew bolt -1- for ATF lines -arrows- from d bgearbox and dis
y V gu
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connect ATF lines. rise nte
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un
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rrectness of i
Unscrew securing bolt -arrow- for ATF lines -1-.
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nform
mercia
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com
tion in
r
te o
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iva
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Cop py
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Unscrew bolt securing ATF double line -1- from bracket -2- and
co lksw
by
cted agen
lay line together with clamp -arrow- to side. Prote AG.
2. Gearbox 29
Amarok 2011
8-speed automatic gearbox 0CM - Edition 04.2013
Note
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
foam surface -arrow- under gearbox -1- and also secure gear
box using a tensioning belt.
l purpos
at
Note
om
ion
c
in t
or
do
priv
cum
or
Press gearbox off engine (dowel sleeves) and pull out to rear.
f
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Cop py
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Prote AG.
Note
pt
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d
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Please observe the following points during all installation work,
rm
ility
ot
itations: wit
, is n
h re
Route lines of all kinds and electrical cables so as to re-
hole
spec
t to the co
a
com
tion in
Caution
r
te o
thi
s
iva
do
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cum
fo
t.
yi
que converter will be damaged.
Co
Cop py
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Before installing gearbox, ensure that torque converter is cted agen
Prote AG.
properly seated in gearbox page 12 .
2. Gearbox 31
Amarok 2011
8-speed automatic gearbox 0CM - Edition 04.2013
ce
e
nl
pt
du
an
If fitted, install engine/gearbox guard General body repairs,
itte
y li
erm
exterior; Rep. gr. 66 ; Engine/gearbox guard; Removing and
ab
ility
installing engine/gearbox guard . ot p
wit
, is n
h re
hole
page 51 .
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Specified torque
m
at
om
io
Component Specified torque
n
c
in t
or
his
Item 2, 3, 6: M1270 80 Nm
ate
do
riv
cum
for
en
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Item 7, 8: M1050 45 Nm
n
t.
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Item 9: M1011590 45 Nm t. C rig
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Item 4: M1270 80 Nm cop Vo
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Item 5: M1260 80 Nm Prote AG.
AG. Volkswagen AG d
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itte
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ab
ility
ot p
wit
, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
Removing
Remove transfer box Power transmission; Rep. gr. 39 ;
nform
ercia
at
io
in t
or
his
e
do
riv
cum
for
en
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t.
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op
bearing behind it. C py
ht. rig
rig ht
Pull out seal using puller - T10055- .
py by
co Vo
by lksw
cted agen
Installing
Prote AG.
2. Gearbox 33
AG. Volkswagen AG d
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Amarok 2011 ut ho eo
ra
a
8-speed automatic
ss gearbox 0CM - Edition 04.2013 c
ce
le
un
pt
an
Especially coat sealing lips of new seal with ATF.
d
itte
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erm
ab
ility
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wit
is n
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ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
First put sleeve - T10180- on output shaft to prevent damage
mer
to seal.
atio
om
n
Drive in new oil seal to stop using thrust piece - T10180- . Do
c
i
or
n thi
not cant oil seal in the process.
te
sd
iva
o
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cum
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fo
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t.
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Finally, check ATF level and top up page 51 .
C py
t. rig
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Prote AG.
3 Assembly mountings
3.1 Removing and installing gearbox carrier/gearbox mount
ing, page 35
AG. Volkswagen AG d
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Removing
pe
ility
ot
wit
, is n
h re
hole
spec
Mark installation position of gearbox crossmember.
es, in part or in w
t to the co
Unscrew securing bolts for gearbox mountings -arrows-.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Assembly mountings 35
Amarok 2011
8-speed automatic gearbox 0CM - Edition 04.2013
Note
gearbox crossmember.
nl
pt
du
an
itte
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erm
ab
Specified torques
ility
ot p
wit
, is n
der frame1)
t to the co
1) Renew.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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co lksw
by
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Prote AG.
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un
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4 Transporting gearbox
itte
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erm
ab
ility
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4.1 Transporting gearbox, page 37
wit
is n
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4.1 Transporting gearbox
ole,
spec
urposes, in part or in wh
Special tools and workshop equipment required
t to the co
Workshop hoist - VAS 6100-
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
en
ng
t.
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Cop py
Lifting tackle - 2024 A- ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
WARNING
4. Transporting gearbox 37
Amarok 2011
8-speed automatic gearbox 0CM - Edition 04.2013
5 ATF circuit
5.1 Assembly overview - ATF circuit, page 38
5.2 Removing and installing ATF cooler, page 39
5.3 Removing and installing ATF lines, ATF cooler/thermo
stat, page 42
5.4 Removing and installing ATF lines, thermostat/gearbox,
page 45
olkswagen AG
en AG. V
5.5 Removing and installing
olksATF filter, page 47
wag does
not
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by ara
5.6 Cleaning ATF circuit,
ris
ed page 49 nte
ho eo
ut ra
5.1 Assembly overview - ATF circuitss
a c
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nl
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du
an
itte
Caution
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ab
ility
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, is n
ing and filling ATF. An improper ATF level hinders the function
h re
hole
of the gearbox.
spec
es, in part or in w
t to the co
1 - ATF cooler
rrectness of i
Removing and installing
page 39
l purpos
2 - Bracket
nform
ercia
3 - Return line
m
at
ion
in t
or
his
e
do
riv
ATF.
p
cum
or
en
ng
t.
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page 42
Co
Cop py
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4 - O-ring
ht
pyri by
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co
Renew after removal
by lksw
cted agen
Prote AG.
Moisten O-ring with ATF
5 - Thermostat
6 - Clamp
7 - Bolt
20 Nm
8 - Bolt
8 Nm
9 - Double line.
Insert to stop by hand
with new O-ring.
Moisten O-rings with
ATF.
Removing and installing
page 45
10 - Bolt
8.5 Nm
11 - Bolt
8 Nm
12 - Thermostat bracket
13 - Bolt
7 Nm
14 - Supply line
Insert to stop by hand with new O-ring.
Moisten O-rings with ATF.
Removing and installing page 42
15 - Bolt
2 Nm
AG. Volkswagen AG d
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pt
Drip tray - V.A.G 1306-
du
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ab
ility
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spec
es, in part or in w
t to the co
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nf
ercia
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om
n in
or c
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
5. ATF circuit 39
Amarok 2011
8-speed automatic gearbox 0CM - Edition 04.2013
Removing
Note
AG. Volkswagen AG d
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nl
pt
du
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ab
ility
ot p
wit
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spec
Lever off clips -arrows- and remove left air duct -1-.
es, in part or in w
t to the co
Place dip tray - V.A.G 1306- under ATF cooler.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
Unscrew right bolt -arrow- and disconnect ATF line -1- from
f
en
ng
t.
ATF cooler -2-.
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Cop py
t. rig
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pyri by
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co lksw
by
cted agen
Prote AG.
Unscrew left bolt -arrow- and disconnect ATF line -1- from ATF
cooler -2-.
AG. Volkswagen AG d
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pt
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Unscrew bolt -arrow- from ATF cooler -1-.
itte
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ility
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es, in part or in w
t to the co
rrectness of i
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ercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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co lksw
by
cted agen
Prote AG.
5. ATF circuit 41
Amarok 2011
8-speed automatic gearbox 0CM - Edition 04.2013
Pull ATF cooler -arrow- upwards out of guide -1- and remove
ATF cooler.
Installing
Install in reverse order of removal, observing the following:
Note
AG. Volkswagen AG d
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Seal open lines and connections using clean plugs from engine
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hole
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Remove front bumper cover General body repairs, exterior;
Rep. gr. 63 ; Front bumper; Removing and installing front
bumper cover .
rrectness of i
If fitted, remove engine/gearbox guard General body re
pairs, exterior; Rep. gr. 66 ; Engine/gearbox guard; Removing
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nf
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Remove connecting hose between charge air cooler and pres
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Unscrew bolts -arrows- and remove front struts -1-.
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Lever off clips -arrows- and remove left air duct -1-.
5. ATF circuit 43
Amarok 2011
8-speed automatic gearbox 0CM - Edition 04.2013
Unscrew bolt -arrow- and pull supply and return lines out of
thermostat.
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Unscrew bolt -arrow- of supply line -1-.
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Checking ATF level and topping up page 51
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Rep. gr. 63 ; Front bumper; Removing
aut
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and installing front eo
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5.4 Removing and installing ATF lines, ther
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mostat/gearbox
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5. ATF circuit 45
Amarok 2011
8-speed automatic gearbox 0CM - Edition 04.2013
AG. Volkswagen AG d
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and installing engine/gearbox guard .
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Place drip tray - V.A.G 1306- underneath.
Unscrew bolt -arrow- of ATF double line -1- from thermostat.
Unscrew bolt -1- of ATF double line -arrows- and pull ATF
double line out of gearbox.
Unscrew bolt securing ATF double line -1- from bracket -2- and
remove line together with clamp -arrow-.
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Seals must always be renewed.
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If ATF cooler or ATF lines have been renewed, they must be
filled page 53 . rrectness of i
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5.5 Removing and installing ATF filter Cop py
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Special tools and workshop equipment required
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5. ATF circuit 47
Amarok 2011
8-speed automatic gearbox 0CM - Edition 04.2013
Removing
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Observe repair instructions page 1 .
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Position used oil collection and extraction unit - V.A.G 1782-
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Carefully pull ATF filter -arrow- downwards in
-direction of arrow- off mechatronic unit -1-.
Installing
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Fit ATF filter to mechatronic unit.
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Fill ATF page 53 .
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Specified torques
1.1 Assembly overview - sump/oil strainer, page 57
WARNING
5. ATF circuit 49
Amarok 2011
8-speed automatic gearbox 0CM - Edition 04.2013
Remove bolt -1- and pull ATF lines out of thermostat -2-.
Unbolt ATF lines from and to ATF cooler at thermostat -2-. In
the process, hold against thermostat.
Remove and drain ATF cooler page 39 .
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Specified torques
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5.1 Assembly overview - ATF circuit, page 38
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6 ATF
6.1 Checking ATF level, page 51
6.2 Draining and filling ATF, page 53
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Used oil collection and extraction unit - V.A.G 1782-
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screw plug for ATF inspection/filler hole located above sump.
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Caution
Test conditions
Gearbox must not be in emergency running mode.
Vehicle must be standing absolutely level.
Gearbox is set to position P.
6. ATF 51
Amarok 2011
8-speed automatic gearbox 0CM - Edition 04.2013
Note
ce
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leads to overfilling.
nl
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Checking the ATF level when the ATF temperature is too high
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The ATF level is checked on the ATF inspection/filler hole.
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The ATF level is correct if ATF is slightly dripping out of ATF
inspection/filler hole at an ATF temperature of 35 C to 45 C
(50 C for hot climate countries), due to the increased ATF
rrectness of i
level at higher temperatures.
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Observe allocation as per Electronic Parts Catalogue .
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The adapter for filling ATF must be clean. The ATF must
not be mixed with other ATF oils!
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With engine running, insert filling hook of ATF filling unit -
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V.A.G 1924- into ATF inspection/filler hole.
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Fill with ATF using ATF filling unit - V.A.G 1924- -arrow- until
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WARNING
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An ATF level which is too low or too high will impair the function
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Tighten new plug.
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While the engine is running,
wait until an ATF temperature of 90 is reached.
Now ensure that this temperature is maintained for 5 minutes,
while the ATF cooler is filled.
Stop engine and let ATF cool off to a temperature of 35 C.
Then check ATF level again.
If fitted, install engine/gearbox guard General body repairs,
exterior; Rep. gr. 66 ; Engine/gearbox guard; Removing and
installing engine/gearbox guard .
Specified torques
Component Specified torque
ATF inspection plug 35 Nm
6. ATF 53
Amarok 2011
8-speed automatic gearbox 0CM - Edition 04.2013
AG. Volkswagen AG d
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Vehicle diagnostic tester rised
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Caution
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Engine off.
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Selector lever in P.
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If ATF temperature is above 45 C, let the gearbox cool off.
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WARNING
Note
Draining ATF:
Position used oil collection and extraction unit - V.A.G 1782-
under gearbox.
Remove ATF drain plug -1- from sump.
Drain ATF.
Adding ATF
Tighten ATF drain plug in sump.
Caution
Caution
box.
un
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The adapter for filling ATF must be clean. The ATF must
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hole
spec
es, in part or in w
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Unscrew plug for ATF inspection/filler hole -2- and insert filling
hook of ATF filling unit - V.A.G 1924- into ATF inspection/filler
hole.
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Cop py
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6. ATF 55
Amarok 2011
8-speed automatic gearbox 0CM - Edition 04.2013
Start engine and immediately fill more ATF until it flows out of
overflow edge -arrow-.
Screw in plug for ATF inspection/filler hole hand-tight.
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Run engine at idling speed. d byV ua
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With brake pressed, shift through au
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at idling speed and make sure each
ss position is engaged for at
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Specified torques
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1.1 Assembly overview - sump/oil strainer, page 57
rrectness of i
Component Specified torque
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Cop py
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38 Gears, control
1 ATF system
1.1 Assembly overview - sump/oil strainer, page 57
1.2 Removing and installing sump, page 58
1.3 Removing and installing hydraulic impulse oil storage with
accumulator solenoid N485 , page 60
1 - Mechatronic unit
Removing and installing
page 62 .
2 - Bolt
Renew after removal
Observe tightening se
quence page 65
8 Nm wage
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page 60
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5 - Bolt
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8 Nm
6 - Seal
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page 47
nform
mer
8 - Solenoids
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1. ATF system 57
Amarok 2011
8-speed automatic gearbox 0CM
AG-. V
Edition 04.2013
olkswagenA n G do
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12 - ATF pan ed
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Removing and installing
tho page 58 or
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13 - Bolt
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Renew after removal
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14 - Seal
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Renew after removal
urposes, in part or in wh
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ATF pump intake
15 - Connecting piece with seal
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Renew after removal
Oil supply for ATF pump
ss o
cial p
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1.2 Removing and installing sump
mer
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Removing
If fitted, remove engine/gearbox guard General body re
pairs, exterior; Rep. gr. 66 ; Engine/gearbox guard; Removing
and installing engine/gearbox guard .
Position used oil collection and extraction unit - V.A.G 1782-
under gearbox.
Unscrew ATF drain plug and drain ATF page 53 .
Note
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Remove sump -1- downwards in -directionlkof
swaarrow-.
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page 47 .
t to the co
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Cop py
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1. ATF system 59
Amarok 2011
8-speed automatic gearbox 0CM - Edition 04.2013
AG. Volkswagen AG d
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Specified torques
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nf
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or
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The hydraulic impulse oil storage is not installed in all gear
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boxes.
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Rules for cleanliness page 6 .
Prote AG.
Removing
Gearbox is installed.
Caution
Caution
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control unit (mechatronic gu unit)
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Remove hydraulic impulse oil storage.
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1. ATF system 61
Amarok 2011
8-speed automatic gearbox 0CM - Edition 04.2013
2 Mechatronic unit
2.1 Removing and installing mechatronic unit, page 62
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WARNING
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Gearbox is installed.
t. C rig
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Shift selector lever to position P.
co lksw
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Switch off ignition and remove ignition key.
Remove ATF sump page 58 .
Remove ATF filter page 47 .
Gearbox with hydraulic impulse oil storage
Remove hydraulic impulse oil storage page 60 .
Caution
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Unscrew bolt and pull catch -1- of connector downwards in
is n
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Caution
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Cop py
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Risk of damaging mechatronic unit.
rig ht
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Only the bolts with Torx T40 heads may be loosened.
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Prote AG.
Note
2. Mechatronic unit 63
Amarok 2011
8-speed automatic gearbox 0CM - Edition 04.2013
Caution
pt
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d
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Note
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tion in
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Install new connector housing (prior to installing bolt -16-).
es, in part or in w
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one specific installation position. Then, lock securing clip.
rrectness of i
Note
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Do not tighten bolt -16- until after the securing clip has been prop
erly locked.
nform
mercia
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Tighten new bolts for mechatronic unit in sequence given.
om
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Tightening sequence for mechatronic unit without hydraulic im
um
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en
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Cop py
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rig ht
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Prote AG.
2. Mechatronic unit 65