Workshop Manual
AG. Volkswagen AG d
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Sharan 2016 ➤
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Tiguan 2008 ➤
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Edition 05.2017
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AG. Volkswagen AG d
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Repair Group ho eo
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00 - Technical data
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nl
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30 - Clutch
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34 - Controls, housing
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35 - Gears, shafts
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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.
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 General safety provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 2
1.3 Notes on tow-starting/towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Safety precautions when using testers and measuring instruments during a road test . . . . 2
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Identification of gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 Allocation gearbox - engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.1 Overview of fitting locations - electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
olkswagen AG
en AG. V
30 - Clutch . . . . . . . . . .Vo.lk.sw. a.g . . . . . . . . . . . . d.oe.s.no.t g. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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1 Clutch . . .ri.se.d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ra.nt.e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ho e
1.1 Assembly aut overview - dual clutch . . . . . . . . . . . . . . . . .o.r a. . . . . . . . . . . . . . . . . . . . . . . . . . 11
s c
1.2 Removing and installing clutch end cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
s 12
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34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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1 Mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
hole
spec
1.1 Removing and installing mechatronic unit for dual clutch gearbox J743 (gearbox installed)
es, in part or in w
........................................................................ 26
t to the co
1.2 Removing and installing mechatronic unit for dual clutch gearbox J743 (gearbox removed)
........................................................................ 31
rrectness of i
1.3 Removing and installing gearbox input speed sender G182 and oil temperature sender in
multi-plate clutch G509 up to gearbox date 05/15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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42
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5 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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5.1 Overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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5.2 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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5.3 Checking selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
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5.4 Adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
agen
Prote AG.
Contents i
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017
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ii Contents
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017
00 – Technical data
1 Safety information
(VRL010440; Edition 05.2017)
⇒ “1.1 General safety provisions”, page 1
⇒ “1.2 Safety measures when working on vehicles with a start/
stop system”, page 2
⇒ “1.3 Notes on tow-starting/towing”, page 2
⇒ “1.4 Safety precautions when using testers and measuring in‐
struments during a road test”, page 2
WARNING
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connecting the battery:
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battery.
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♦ Disconnect battery only after the ignition has been switch‐ spec
es, in part or in w
ed off.
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1. Safety information 1
Sharan 2016 ➤ , Tiguan 2008 ➤
olkswagen AG
7-speed dual clutch gearbox 0BH - Edition 05.2017swagen AG. V does
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1.2 Safety measures when working on ve‐
e nte
ris
tho eo
hicles with a start/stop system au ra
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Observe the following when working on vehicles with a start/stop
an
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system:
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Injury hazard as a result of automatic engine start in vehicles
with start/stop system. urposes, in part or in wh
t to the co
♦ In vehicles with the start/stop system activated (identifia‐
ble by an indication in the dash panel insert) the engine
rrectne
can start automatically if required.
♦ When working on the vehicle, always make sure that the
ss
start-stop system is deactivated (switch off the ignition;
o
cial p
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switch the ignition on again if necessary).
inform
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Caution
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Danger of irreparable damage to gearbox. t. Cop py
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♦ If the vehicle must be towed, the selector lever must be in yri
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the “N” position, and the vehicle must be towed at a speed
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no greater than 50 km/h and for a distance not exceeding
Prote AG.
50 km.
Note
WARNING
Please note the following to avoid personal injury and damage to,
or destruction of, electrical and electronic components:
♦ Connect and disconnect measuring and testing devices only
with the ignition switched off.
Caution
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1. Safety information 3
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017
2 Identification
1 - Gearbox code
2 - Day of production
3 - Month of production
4 - Year of production
5 - Serial number
6 - Minute of production
7 - Hour of production
8 - Factory
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3 Repair notes
⇒ “3.1 General information”, page 5
⇒ “3.2 Rules for cleanliness”, page 5
⇒ “3.3 General repair instructions”, page 6
⇒ “3.4 Gaskets and seals”, page 7
⇒ “3.5 Nuts and bolts”, page 7
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clutch pedal.
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Selector mechanism
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spec
The feedback for the gearbox concerning the selector lever po‐
es, in part or in w
t to the co
lever cable and the multifunction switch (gear sensor) any more,
as is the case for the automatic gearbox. The information con‐
cerning selector lever positions or shifting operations are trans‐
ferred to the gearbox control unit via a separate control unit in the rrectness of i
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selector mechanism and the CAN data bus. That is, gears are
shifted without any mechanical cables being involved. Only for
selector lever position “P” the parking lock is engaged mechani‐
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engine output. C py
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• Gear change map for extreme downhill stretches is matched
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to the braking effect of the engine. Prote
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3. Repair notes 5
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017
ce
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or Test Instruments .
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Special tool
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Gearbox
es, in part or in w
t to the co
Always make sure that no dirt can enter an »open« gearbox. In
particular, dirt entering an »exposed« mechatronic unit for dual
clutch gearbox - J743- and/or oil pump can lead to gearbox failure.
rrectness of i
♦ If gearbox covers have been unbolted or gearbox has no fluid,
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Locking devices
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♦ Do not overstretch retaining rings.
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♦ Always renew retaining rings which have been damaged or
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overstretched.
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♦ Retaining rings must locate properly in grooves.
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Dual clutch gearbox oil
The oil quality is of critical importance for the function of the gear‐
box.
Shake oil bottle before opening.
Do not mix additives in oil. Do not fill any other oil.
Oil which has been drained out cannot be filled again.
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♦ Loosen and tighten securing bolts and securing nut for covers
hole
spec
t to the co
♦ Specified torques given are for unoiled nuts, bolts and screws.
♦ Clean threads of bolts which are to be installed with locking
fluid using a wire brush. Then insert bolts with locking fluid -
rrectness of i
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3. Repair notes 7
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017
4 Technical data
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2.0 l - 100, 103 2.0 l - 130 kW TDI 2.0 l - 110, 135
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kW TDI kW TDI
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hole
spec
4.1.2 Sharan 2016 ►
es, in part or in w
t to the co
Take account of the gearbox code if spare parts are required for
a repair.
rrectness of i
Allocation: gearbox codes for diesel engines
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QYQ, SCY
2.0 l - 110, 135
nform
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kW TDI
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Changing approx. 5.5 litres
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♦ Change interval: ⇒ Maintenance manual and/
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or ⇒ service tables “ELSA” p by
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Lubricant Dual clutch gearbox oil
The oil is available as a replacement part; part no. ⇒ Electronic
parts catalogue (ETKA) .
Further information in the part number designates the container
size.
AG. Volkswagen AG d
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4. Technical data 9
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017
5 Electrical components
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⇒ page 47 Selector
hole
spec
mechanism
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t to the co
rrectness of i
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30 – Clutch
1 Clutch
⇒ “1.1 Assembly overview - dual clutch”, page 11
⇒ “1.2 Removing and installing clutch end cover”, page 12
⇒ “1.3 Removing dual clutch”, page 15
⇒ “1.4 Installing dual clutch”, page 18
Caution
The
♦ drive plate has to re‐
main engaged between
the teeth of the outer
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If♦the drive plate de‐ ir se
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taches, the plates in the tho tee
or
dual clutch can shift. It ss
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may then not be possible
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❑ 10 shims having differ‐
hole
spec
ent »thicknesses«.
es, in part or in w
0.05 mm increments.
❑ Thickness of spacer ring
must be determined
rrectness of i
clutch.
6 - Dual clutch end cover
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1. Clutch 11
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017
Caution
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Brief description
The cover is held in its seat by a retaining ring. After the retaining
ring has been removed, the cover can be levered out of its seat.
rrectness of i
Removing
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– Secure gearbox to assembly stand ⇒ page 86 .
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Often, doubts arise as to whether the filter must be renewed or
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Note
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– Lever out retaining ring -2- of clutch end cover using screw‐
driver -1- -arrow- and remove.
rrectne
Cover can be levered out with a screwdriver.
ss o
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Note
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Install only a »new« cover.
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Installing
Caution
1. Clutch 13
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017
Note
WARNING
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ility
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spec
es, in part or in w
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of clutch shaft.
– Moisten outer seal of cover with oil.
nf
ercia
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m
atio
Caution
om
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Moisten only the outer seal of the cover with oil. Oiling the inner
te
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– Guide cover horizontally over sleeve and press evenly onto its
seat.
Caution
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– Do not remove
olks
wbush
age until retaining ring
does is installed.
no
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– Installing
ris
ed gearbox ⇒ page 82 nte
tho eo
– sTop
s a up gear oil ⇒ page 105 .
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WARNING
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♦ 2 x hooks - 3438-
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1. Clutch 15
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017
♦ Puller - T10055-
♦ Puller - T10525-
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• The axial play of the clutch is readjusted during installation
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procedure. utho
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• To remove or install clutch, gearbox must be securely attached
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without error.
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Removing
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– Remove clutch end cover ⇒ page 12 .
hole
spec
es, in part or in w
If there is no marking:
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marked position.
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Note
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t.
yi Co
The retaining ring is renewed together with the clutch. If the clutch Cop py
which is removed is reinstalled, the securing ring is to be used
t. rig
gh ht
yri by
again as well. cop Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
splines and carefully pull drive plate off its seat -arrows-.
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
– Remove retaining ring -arrow- and save it for now.
AG.
Note
1. Clutch 17
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Engage 2 hooks - 3438- on opposite sides of clutch -arrow-.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
– Remove dual clutch using hooks - 3438- . Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Caution
Brief description
• To remove or install the clutch, the gearbox must be securely
attached to an assembly stand in vertical position.
• The large plate carrier goes through all plates inside the clutch.
It must not slip out of the lowest plate.
1. Clutch 19
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017
Installing
AG. Volkswagen AG d
– Take great care when removing the dual clutch from its pack‐lkswagen oes
not
age. db
yV
o gu
ara
e nte
ris
– Turn piston rings by hand. They must move freelyuand
tho must eo
ra
not bind. ss a c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Ensure that piston rings -1-, -2-, -3- and -4- are seated cor‐
rectly. The ring butts -arrows- of piston rings -1- and -3- should
rrectness of i
align.
l purpos
– The ring butts -arrows- of piston rings -2- and -4- should align
and be offset 180° to the ring butts of piston rings -1- and -3-.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
Important! Position of drive plate gh ht
pyri by
Vo
co lksw
by
– Before installing, check if there is a marking -arrow- on dual Prote
cted AG.
agen
clutch.
– If there is no marking, use a permanent marker to make a col‐
our marking on the drive plate and one the outer plate carrier.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
The dual clutch is properly fitted if there is horalmost
is no play in the nte
eo
retaining pin - T10524- . s aut ra
c
s
ce
e
nl
pt
du
an
Note
itte
y li
erm
ab
ility
ot p
♦ The retaining pin remains inserted until the clutch end cover
wit
is installed.
, is n
h re
hole
♦ The dual clutch must now not be rotated any more, as this can
spec
shift the position of the retaining pin - T10524- .
es, in part or in w
t to the co
rrectness of i
– Lever out retaining ring -2- of drive plate using screwdriver
l purpos
-1- -arrow-.
nf
ercia
o
Note
rm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Clutch 21
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017
Note
Caution
Do not lift (not even slightly) or remove plate carrier! The plates
could turn.
ce
e
nl
pt
du
an
itte
y li
– Screw universal dial gauge - VW 387- to gearbox flange.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Set -tip of dial gauge- on input shaft.
rrectness of i
– Set -dial gauge- to 0 with preload.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Lift dual clutch with force -in direction of arrow- to stop using
hooks - 3438- and note measurement.
– Call this value “A”.
Note
Second measurement
• The retaining pin - T10524- remains installed!
Note
an
itte
y li
ab
ility
ot p
be fitted.
h re
hole
spec
– Note result.
es, in part or in w
t to the co
WARNING
nf
ercia
atio
om
n in
c
Example:
or
thi
te
sd
iva
cu
o
m
f
1.28 mm 1.3 mm
en
ng
t.
yi Co
op
1.26 mm 1.3 mm
C py
ht. rig
rig ht
py by
co Vo
by lksw
– Remove old retaining ring -arrow-. cted agen
Prote AG.
Note
1. Clutch 23
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH. V-oEdition
lkswage 05.2017
AG n AG d
agen oes
olksw not
– Fit calculated shim. db
yV gu
ara
rise nte
Third measurement (checktho measurement) eo
s au ra
c
s
To make sure that the shim is correct, a test measurement must
ce
e
nl
still be carried out. Proceed as follows:
pt
du
an
itte
y li
• The retaining pin - T10524- remains installed!
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Install old retaining ring -arrow- once more.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
– Set tip of dial gauge -on hub of large plate carrier-.
cop Vo
by lksw
cted agen
Prote AG.
Note
ce
le
pt
place and press outwards slightly.
an
d
itte
y li
rm
ab
– Carefully drive the drive plate onto its seat using thrust piece
pe
ility
- T10426- and a plastic mallet.
ot
wit
, is n
h re
– Install drive plate retaining ring.
hole
spec
– Starting at the opening, press retaining ring in clockwise di‐
es, in part or in w
t to the co
rection into its fitting position.
• The retaining ring must be fully engaged.
rrectness of i
– Use screwdriver to check that retaining ring is correctly seated
and engaged.
l purpos
nform
ercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Clutch 25
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017
34 – Controls, housing
1 Mechatronic unit
⇒ “1.1 Removing and installing mechatronic unit for dual clutch
gearbox J743 (gearbox installed)”, page 26
⇒ “1.2 Removing and installing mechatronic unit for dual clutch
gearbox J743 (gearbox removed)”, page 31
⇒ “1.3 Removing and installing gearbox input speed sender G182
and oil temperature sender in multi-plate clutch G509 up to gear‐
box date 05/15”, page 37
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi
Always make sure that no dirt can enter an »open« gearbox.
Co
Cop py
t. rig
gh
In particular, dirt entering an »exposed« mechatronic unit for dual
ht
pyri by
Vo
o
clutch gearbox - J743- can lead to gearbox failure. by c lksw
cted agen
Prote AG.
Please also refer to the notes on the oil filter change regarding
»dirty oil« ⇒ page 101 .
Remove mechatronic unit.
– Move selector lever to position “P”.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation; Assembly overview - noise in‐
sulation
n AG. Volkswagen AG do
Note lks wage es n
o ot g
byV ua
d ran
ir se
It is possible that parts having nothing
tho to do with the mechatronic tee
or
unit must be removed. This depends
ss
au
on the vehicle's equipment. ac
This will create enough space to remove the mechatronic unit.
ce
le
un
pt
an
d
itte
y li
– Unbolt wiring retainer from front of »large« gearbox cover (2
rm
ab
nuts M6).
pe
ility
ot
wit
, is n
h re
– Release mechatronic unit connector by turning in
hole
spec
es, in part or in w
t to the co
– Raise lines near cover and tie.
– Place used oil collection and extraction unit - V.A.G 1782- be‐
low gearbox.
rrectness of i
– Drain oil ⇒ page 105 .
l purpos
nform
mercia
a
com
tion in
r
te o
thi
– Remove securing clip -3-.
s
iva
do
r
rp
cum
– Unscrew bolts -1- diagonally and remove.
fo
en
ng
t.
yi Co
– Remove cover -2- with seal. t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
Note
cted agen
Prote AG.
Always renew bolts, securing clips and the cover with seal.
1. Mechatronic unit 27
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017
solenoid valves.
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
WARNING
ce
e
nl
⇒ page 37 .
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
orm
m
Caution
atio
om
n in
or c
solenoid valves.
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Mechatronic unit 29
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
at
om
io
Caution
n
c
in t
or
his
ate
en
g
t.
yi Co
for dual clutch gearbox - J743- must be renewed. Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
Continuation for all:
agen
Prote AG.
– Set new cover with seal -2- in place and tighten with new bolts
-1- diagonally in several stages to 10 Nm + 45°.
– Install new securing
agenclip -3-.
AG. Volkswagen AG d
oe w s no
olks t
– Attach wire
ed
byretainer to cover and tighten nutsguto
V
ara10 Nm.
is nte
or
– Push au
thon connector for mechatronic unit for dual clutch
eo
r agearbox
- J743-
ss and engage lock by turning. c
ce
e
nl
an
itte
ab
charge air cooling . ility
ot p
wit
, is n
h re
hole
spec
t to the co
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Mechatronic unit 31
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
is nte
Always make sure that no dirt can enter an »open«
hor gearbox. eo
aut ra
s c
In particular, dirt entering an »exposed« mechatronic
s unit for dual
ce
le
pt
an
d
itte
y li
Please also refer to the notes on the oil filter change regarding
erm
ab
»dirty oil« ⇒ page 101 .
ility
ot p
wit
is n
t to the co
– Remove securing clip -3-.
Always renew securing clip.
rrectne
f inform
Note
mer
atio
om
Always renew bolts, securing clips and the cover with seal.
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– If fitted, release connector -1- of gearbox input speed sender
es, in part or in w
t to the co
G509- using release tool - T10465- .
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
c
– Remove bolts -arrows- diagonally. um
fo
en
ng
t.
yi
All 9 bolts have same length and are not allowed to be reused.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Mechatronic unit 33
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017
Caution
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Lay mechatronic unit to side properly.
rrectness of i
– Put down mechatronic unit so that sensors -arrows- are point‐
l purpos
ing upwards.
Install mechatronic unit.
nform
ercia
a
com
the following:
tion in
r
te o
thi
s
WARNING
iva
do
r
rp
cum
fo
t.
yi Co
face on the gearbox housing thoroughly without using cleaning Cop py
agents. Always make sure that no dirt can get into the inside.
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Caution
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f in
– Tighten bolts in specified sequence to 8 Nm + 45°.
form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Mechatronic unit 35
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017
Caution
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
or
– Renew seal -arrow-. ss
au ac
ce
e
pt
du
an
itte
y li
– Lubricate seal with ⇒ DSG oil.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Set new cover -2- in place and tighten with new bolts -1- di‐
agonally in several stages to 10 Nm + 45°.
nform
ercia
at
om
in t
or
do
riv
cum
or
gearbox - J743- .
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Brief description
Both senders are combined in one component and can be re‐
newed together only. They are in the gearbox near the multi-
clutch. Before removal, the mechatronic unit for dual clutch
gearbox - J743- must be removed.
Removing
– Remove mechatronic unit for dual clutch gearbox - J743-
⇒ page 26 .
Do not pull on line!
– Unscrew and remove bolt -2- and pull out sender -1-.
Installing
Install in reverse order of removal. During this procedure, observe
the following:
AG. Volkswagen AG d
agen
Reinstall »old« sender only if: Volksw
oes
not
by gu
d ara
• The sender has no defect orise nte
th eo
u ra
• The cable was not pulled on when
ss a it was removed c
ce
e
nl
an
itte
y li
ab
ility
ot p
⇒ page 26 .
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
37
AG.
1. Mechatronic unit
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
Removing
yi Co
Cop py
t. rig
– Move selector lever to position “P”. gh ht
pyri by
Vo
co lksw
by
– Remove air filter housing. Prote
cted AG.
agen
Caution
Installing
Install in reverse order of removal. During this procedure, observe
the following:
n AG. Volkswagen AG do
wage es n
– Renew O-rings -C-. yV
olks ot g
ua
b
ed ran
– Set gear oil cooler -B- in place. When doing tthis,
hor note O-rings
is tee
or
-C-. au ac
ss
ce
– Screw in new bolts -A- and tighten to 20 Nm + 45°.
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
io
– Attach coolant hoses to gear oil cooler and remove hose
n
c
in t
r
clamps -3094- .
o
his
ate
do
riv
cum
for
t.
yi Co
moving and installing battery . t. Cop py
rig
gh ht
– Install air filter housing. yri
p by
co Vo
by lksw
cted
♦ Petrol engine: ⇒ Rep. gr. 24 ; Air filter; Removing and instal‐
agen
Prote AG.
ling air filter housing
♦ Diesel engine: ⇒ Rep. gr. 23 ; Air filter; Removing and instal‐
ling air filter housing
– Check coolant level and top up with coolant as needed ⇒ Rep.
gr. 19 ; Removing and installing parts of cooling system .
– Checking and adjusting oil level ⇒ page 103 .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
– Insert screwdriver -1- between collar of gearbox and breather
ce
e
nl
pt
du
pipe -2-.
an
itte
y li
erm
ab
– Pry off breather pipe -2- with screwdriver -1-.
ility
ot p
Installing
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Put on cap.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– Press yellow plastic part -arrow- from above and hold in this
wit
, is n
position.
h re
hole
spec
Lever can now be moved from position »P«.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Wedges - T10383/1-
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op py
Brief description
t. C rig
gh ht
pyri by
Vo
o
Handle is removed together with selector cover. by c lksw
cted agen
Prote AG.
Removing
– Shift selector lever to position “D”.
The push button -arrow- does not need to be pulled out by hand.
Push button engages automatically in installation position when
handle is pulled off.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
orm
m
atio
om
Note
n in
or c
thi
te
sd
a
o
r
rp
cu
m
f
en
ng
t.
yi Co
op
Installing C py
t. rig
gh ht
yri by
Install in reverse order of removal, observing the following:
cop Vo
by lksw
cted agen
Prote
• Selector lever is in position “D”.
AG.
Note
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
44
by lksw
cted agen
Rep. gr.34 - Controls, housing Prote AG.
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017
Note
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
If the button was pressed by mistake, the installation position can
be restored.
l purpos
There are 2 ways of moving the push button into the installation
position, »with« and »without« installation guard. Both of them are
nform
ercia
described here.
m
a
com
tion:
r
te o
thi
s
iva
en
ng
t.
When using the installation guard, make sure that it has an eyelet
yi Co
op
-arrow- at the front. Other types of installation guard are not suit‐
C py
t. rig
gh
able.
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
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ir se tee
tho
u or
– Using a screwdriver,
ss
a press the small lever -1- for the tie rod ac
into the groove -2-. This action presses the push button -3- into
ce
le
un
pt
installation position.
an
d
itte
y li
ab
ility
ot p
h re
ole,
spec
urposes, in part or in wh
Note
t to the co
pressed.
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
⇒ “5.1 Overview - selector mechanism”, page 47
un
pt
an
d
itte
y li
⇒ “5.2 Removing and installing selector mechanism”, page 48
rm
ab
pe
ility
⇒ “5.3 Checking selector lever cable”, page 51
ot
wit
, is n
h re
⇒ “5.4 Adjusting selector lever cable”, page 52
hole
spec
es, in part or in w
t to the co
WARNING
rrectness of i
lever into position “P” and apply handbrake.
l purpos
nform
mercia
a
com
t
1 - Handle with selector cover
ion in
r
thi
without reason. For
s
iva
do
r
cum
fo
en
ng
t.
unclipped ⇒ page 41 .
yi Co
Cop py
t.
❑ Removing and installing
rig
gh ht
yri by
⇒ page 42 cop Vo
by lksw
cted agen
Prote
2 - Selector lever and selector
AG.
5. Selector mechanism 47
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017
Note
Removing
– Remove selector lever handle ⇒ page 42 .
– Remove centre console ⇒ Rep. gr. 68 .
n AG. Volkswagen A
– Separate electrical connector from selector
olks
wagmechanism
e
to ve‐G does no
hicle wiring harness. db
y V t gu
ar
e an
ris tee
– Remove air filter housing. tho or
au ac
ss
♦ Petrol engine: ⇒ Rep. gr. 24 ; Air filter; Removing and instal‐
ce
le
un
y li
ab
pe
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Caution
Note
pt
du
an
itte
ab
Installing
wit
, is n
h re
hole
orm
atio
m
n in
c
thi
te
sd
a
o
r
rp
cu
o
en
ng
t.
yi Co
op
– Adjust selector lever cable after installing ⇒ page 52 . C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5. Selector mechanism 49
AG. Volkswagen AG d
agen oes
ksw not
Sharan 2016 by V ➤ , Tiguan 2008 ➤
ol
gu
ara
d
7-speed orise dual clutch gearbox 0BH - Edition 05.2017 nte
eo
th
au ra
s c
5.2.2 Removing and installing selector mech‐
s
ce
e
nl
pt
du
an
itte
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erm
ab
Brief description
ility
ot p
wit
, is n
h re
be separated from one another. Both are removed together.
hole
spec
es, in part or in w
t to the co
A cord must be attached to the Bowden cable before it is removed.
The cord is needed to guide the Bowden cable between the tunnel
and the heat shield.
rrectness of i
The selector mechanism with selector lever cable can also be
l purpos
nf
ercia
orm
m
atio
om
n in
c
thi
gr. 68 ; Centre console; Removing and installing centre con‐
te
sd
iva
sole .
o
r
rp
cu
o
m
f
t.
yi
hicle wiring harness.
Co
Cop py
t. rig
gh
– Remove air filter housing.
ht
pyri by
Vo
co lksw
by
cted
♦ Petrol engine: ⇒ Rep. gr. 24 ; Air filter; Removing and instal‐
agen
Prote AG.
ling air filter housing
♦ Diesel engine: ⇒ Rep. gr. 23 ; Air filter; Removing and instal‐
ling air filter housing
Caution
– Remove 4 bolts.
ce
le
un
pt
– Carefully pull selector mechanism with Bowden cable out of
an
d
itte
y li
the centre tunnel. Ensure that the cord remains accessible
erm
ab
from the engine compartment after being pulled by the Bow‐
ility
ot p
den cable.
wit
is n
h re
– Remove cord from Bowden cable.
ole,
spec
urposes, in part or in wh
Installing
t to the co
Install in reverse order of removal, observing the following:
A second mechanic is needed to guide Bowden cable from pas‐
rrectne
senger compartment into engine compartment.
ss o
Note
cial p
f inform
mer
atio
om
n
♦ Do not grease selector lever cable.
c
i
or
n thi
te
sd
va
– Attach Bowden cable to cord which was drawn into the pas‐
i
o
pr
cum
r
en
ng
t.
yi Co
– Carefully guide selector mechanism with Bowden cable Cop py
t. rig
through opening in centre tunnel. opyri
gh by
Vo
ht
c lksw
– Have the second mechanic pull cord with Bowden cable
by
cted agen
Prote
through tunnel from engine compartment until Bowden cable
AG.
5. Selector mechanism 51
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017
Caution
G. Volkswagen AG d
– Carefully push locking mechanisms of selector lever cable to‐ lkswagen A oes
not
gether -arrows- and remove selector lever cable upwardsdoutby
Vo gu
ara
of cable support bracket. or
ise nte
th eo
– Do not bend or kink cable. au ra
c
ss
ce
e
nl
– Shift selector lever several times from position »P« to »S« and
pt
du
an
back to »P«.
itte
y li
erm
ab
• Selector lever must move easily.
ility
ot p
wit
, is n
– Reinstall cable.
h re
hole
spec
– Adjust selector lever cable. ⇒ page 52
es, in part or in w
t to the co
Continue installation in reverse order of removal.
rrectness of i
Special tools and workshop equipment required
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
erm
ab
to install it free of tension.
ility
ot p
Adjusting:
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
push lever opposite to driving direction to rear stop.
rrectne
Note
ss
Raise vehicle, to be sure that the gearbox is in “P” (parking lock
o
cial p
f
engaged). It should not be possible to turn both front wheels to‐
inform
gether in the same direction.
mer
atio
om
n
c
i
– Loosen bolt -2- of the Bowden cable -1-.
or
n thi
te
sd
va
o
pr
cum
but under no circumstances must you shift out of “P”.
r
fo
en
ng
t.
yi
In this way the ⇒ inner cable of the Bowden cable finds it optimal
Co
Cop py
position.
t. rig
gh ht
pyri by
Vo
o
– Tighten bolt -2- to 15 Nm.
c by lksw
cted agen
Prote AG.
5. Selector mechanism 53
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017
ce
54 e
nl
pt
du
an
itte
y li
⇒ “6.3 Selector lever in position Tiptronic ”, page 54
erm
ab
ility
ot p
wit
, is n
h re
⇒ “6.5 Selector lever position indicator”, page 55
hole
spec
It must not be possible to start the engine in the selector lever
es, in part or in w
t to the co
positions “R”, “D” or “S”.
On right-hand drive vehicles, the starter must operate only in se‐
lector lever positions “P” and “N” when the locking button in the
rrectness of i
selector lever handle is not pressed.
l purpos
Over 5 km/h
When the selector lever is shifted to “N”, the selector lever lock
nf
ercia
o
solenoid must not lock the selector lever. Selector lever can be
rm
m
atio
om
n in
c
Under 5 km/h
or
thi
te
sd
a
When the selector lever is shifted to “N”, the selector lever lock
iv
o
r
rp
cu
solenoid must lock the selector lever only after approx. 1 second.
o
m
f
t.
yi
pedal is depressed.
Co
Cop py
t. rig
gh ht
6.1 Selector lever in “P” position and ignition pyri by
Vo
o
by c lksw
switched on
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1 - Retaining ring
❑ Renew
2 - Clutch end cover
❑ A cover which has been
removed must not be in‐
stalled again.
❑ Lubricate external seal
with dual clutch gearbox
oil - G 052 182 A2- be‐
fore installing.
❑ Removing and installing
⇒ page 12
3 - Retaining ring
❑ Renew
4 - Shim
❑ Determine thickness
again if a new clutch has
been fitted ⇒ page 11 agen
AG. Volkswagen AG d
oes
olksw not
5 - Tapered ring ed byV gu
ara
ris nte
6 - Clutch aut
ho eo
ra
s c
❑ Removing and installing s
ce
le
⇒ page 11
un
pt
an
d
itte
y li
7 - Seal, right
erm
ab
ility
wit
⇒ page 116
is n
h re
ole,
8 - Breather pipe
spec
urposes, in part or in wh
⇒ page 40
9 - Breather cap
rrectne
10 - Plug
s
11 - Seal
s o
cial p
❑ Renew
inform
mer
n
c
i
or
n thi
13 - Bolt, 20 Nm + 45°
te
sd
va
❑ Renew
i
o
pr
cum
r
fo
en
ng
14 - Filter housing, 20 Nm
t.
yi Co
Cop py
15 - Seal ht. rig
rig ht
py by
❑ Renew co Vo
by lksw
cted agen
Prote AG.
16 - Heat shield
17 - Oil filter
n AG. Volkswagen AG do
❑ Renewing ⇒ page 101 lkswage es n
o ot g
byV ua
d
18 - Bolt, 5 Nm + 90° o
ir se
ran
tee
th or
❑ Renew au ac
ss
ce
le
19 - Cable support bracket
un
pt
an
d
❑ For selector lever cable to gearbox
itte
y li
erm
ab
20 - Gearbox selector lever
ility
ot p
wit
21 - Bolt, 10 Nm + 90° is n
h re
ole,
❑ Renew
spec
urposes, in part or in wh
22 - Gearbox
t to the co
23 - Seal, left
❑ Removing and installing ⇒ page 114
rrectne
24 - Seal
ss
❑ Renew
o
cial p
f in
25 - Oil drain plug, 20 Nm
form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
c
Caution
um
r
fo
en
ng
Comply
♦ with the torque
t.
yi Co
op
setting precisely.
C py
t. rig
gh ht
yri by
The
♦ oil level pipe can cop Vo
by lksw
break between the
cted agen
Prote AG.
thread and the collar.
Note
ce
e
nl
33 - Cover
pt
du
an
itte
❑ With seal
y li
erm
ab
❑ Renew
ility
ot p
wit
, is n
34 - Bolt, 10 Nm + 45°
h re
❑ Renew hole
spec
es, in part or in w
35 - Securing clip
t to the co
❑ Renew
36 - Seal
rrectness of i
❑ Renew
l purpos
nf
ercia
o
7.1.1 Renewing bleeder
rm
m
atio
m
Removing
o
n in
or c
thi
e
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
pt
y li
rm
ab
ility
ot
h re
– Pierce centre of cap with a knife -1- and remove rubber coating
t to the co
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
Installing
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
– Using key - T40297- , drive new sealing cap into gearbox
housing to stop. Take care not to cant sealing cap.
rrectne
– Check gear oil level ⇒ page 103 .
– Install front left wheel housing liner ⇒ General body repairs,
ss
exterior; Rep. gr. 66 ; Wheel housing liner; Removing and
o
cial p
f i
installing front wheel housing liner .
nform
mer
atio
m
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
♦ Support - 10 - 222 A-
h re
hole
spec
t to the co
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi
♦ Adapter - 10 - 222 A /16-
Co
Cop py
t. rig
gh
♦ Hose clamps up to 40 mm - 3093- if available, or hose clamps
ht
pyri by
Vo
o
up to 25 mm - 3094-
c by lksw
cted agen
Prote AG.
♦ Socket insert - T10035-
♦ Socket insert - T10061-
♦ Counter-hold tool - T10172-
♦ Drip tray for workshop hoist - VAS 6208-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
♦ Shackle - 10 - 222 A /12- ility
ot p
h re
hole
Removing
spec
es, in part or in w
height.
– Turn steering to straight-ahead position.
rrectness of i
at
om
in t
or
cum
for
t.
yi
27 ; Battery; Removing and installing battery .
Co
Cop py
t. rig
gh
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Removing
ht
pyri by
Vo
o
and installing starter
c by lksw
cted agen
Prote AG.
– Pry selector lever cable off selector shaft lever -arrow- using
an open-ended spanner.
Caution
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
olkswagen AG
en AG. V
– Remove drive shaft kswheat shield, if present, efrom
ag do s
not bevel box ⇒
Vol
Running gear, ed b axles, steering; Rep. gr. 40 ; Repairing
y gu
ara drive
shafts . horis nte
e
t or
au a
– Pressss both drive shafts off gearbox and remove. ⇒ Rep.c gr.
40 ; Removing and installing drive shaft
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
straps - T10038- .
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
a
com
tio
– Unscrew bolts -A and B-, and remove gearbox carrier for bevel
n in
r
box.
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
tightening propshaft.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
– Secure support - T10323- with a bolt on inside rear threaded
c
in t
or
his
ate
do
riv
cum
for
en
g
t.
yi Co
Cop py
ht. rig
rig ht
py by
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anti-clockwise -arrow-.
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A bolt is located in the starter motor hole -arrow-. This bolt can be
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view - subframe
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– Unscrew bolts -A and B-, and remove gearbox carrier for bevel
box.
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hole for subframe.
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AG.
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AG. Volkswagen AG d
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c
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1 - Direction of travel
- M12 bolts
❑ 80 Nm
❑ 65 Nm, if 18 mm insert -
T10179- is used.
- M10 bolts
❑ 40 Nm
- 2 dowel sleeves in engine
-arrows-
AG. Volkswagen AG d
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c
Component Nm
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Heat shield for right drive shaft to bevel box 20
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cted ⇒ Propshaft and rear final drive; Rep. gr. 39
AG.
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Suspension link, coupling rod, pendulum support, ⇒ Running gear, axles, steering; Rep. gr. 40 .
drive shaft
Wheel bolts ⇒ Running gear, axles, steering; Rep. gr. 44 ; Torque
settings for wheel bolts
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2. Tighten -A- 40 Nm
3. Tighten -B- 40 Nm
rrectne
Petrol engine
ss o
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mer
Item Bolt
atio
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1 M10 x 45
n
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2. Tighten -2- 40 Nm Prote
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Version 1:
♦ Bolts -arrows- 9 Nm
Version 2:
♦ Bolt -A-: 20 Nm
♦ Bolt -B-: 40 Nm
AG. Volkswagen AG d
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Example: securing gearbox to assembly stand.
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ion
c
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10 Bevel box
⇒ “10.1 Removing and installing bevel box, vehicles with 2.0 l -
100/103/130 kW diesel engine”, page 87
⇒ “10.2 Removing and installing bevel box, vehicles
AG. Volkswwith petrol
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⇒ “10.3 Detaching bevel box
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ra
page 97 ss c
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un
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10.1 Removing and installing bevel box, ve‐
an
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hicles with 2.0 l - 100/103/130 kW diesel
erm
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box cannot be renewed individually. It must be removed together
urposes, in part or in wh
with dual clutch gearbox and only then detached from gearbox.
t to the co
⇒ “8 Removing and installing gearbox”, page 61
rrectne
10.2 Removing and installing bevel box, vehicles with petrol engine and vehicles
with 2.0 l - 110/135 kW diesel engine
ss o
cial p
f inform
mer
atio
om
n
c
i
or
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pr
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t.
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Cop py
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by
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AG. Volkswagen AG d
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urposes, in part or in wh
t to the co
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mer
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c
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– Depress brake pedal and loosen bolt of right drive shaft
an
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-arrow- (2nd mechanic needed)⇒ Running gear, axles, steer‐
erm
ab
ing; Rep. gr. 40 ; Repairing drive shafts; Removing and
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Note
t to the co
So that the propshaft can be turned later in order to loosen it:
rrectne
– Move selector lever to »N« position.
– Remove noise insulation below engine and gearbox. ⇒ Gen‐
ss
eral body repairs, exterior; Rep. gr. 50 ; Noise insulation .
o
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Vehicles with diesel engine:
mer
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i
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t
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pr
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view - electric coolant pump . Cop
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Continued for all vehicles: rig ht
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overview - emission control .
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hole
spec
place ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Assembly
es, in part or in w
overview - silencer .
t to the co
If fitted, remove heat shield for propshaft.
Version 1: rrectness of i
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– Unscrew bolts -A- and -B- from bevel box, and remove heat
agen
Prote AG.
shield -1-.
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Prote AG.
10. Bevel box
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017
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spindle of engine support - T50015- . Avoid collisions between
an
d
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components and radiator cowl.
rm
ab
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– Unbolt gearbox carrier.
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Petrol engine:
hole
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– Unscrew bolts -1-, -2- and -3-, and remove bevel box carrier.
rrectness of i
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com
tion in
r
te o
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t.
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Cop py
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rig ht
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Continuation for all:
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– Remove upper securing bolts -arrows- securing bevel box to
l purpos
gearbox.
nform
mercia
a
com
tion in
r
te o
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Cop py
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– Loosen lower securing bolts securing bevel box to gearbox
AG.
AG. Volkswagen AG d
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pt
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Installing
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Note
Caution
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– Screw on bevel box with new bolts -arrows- until finger-tight,kswagen AG does
not
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AG. Volkswagen AG d
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When removing and installing thethobevel box, do not damage the
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s au Renew propshaft if damaged. ra
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– Join bevel box and propshaft by turning spindle of engine sup‐
port - T50015- .
rrectness of i
– Remove engine support - T50015- together with bracket -
T10346/1- .
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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t.
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– Bolt propshaft onto bevel box -arrows- ⇒ Rep. gr. 39 ; Re‐
Co
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t. C rig
gh ht
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– If present, install heat shield for propshaft.
c by lksw
cted agen
Prote AG.
Version 1:
Version 2:
– Bolt on pendulum support using »new« bolts. Specified tor‐
ques ⇒ Running gear, axles, steering; Rep. gr. 40 .
– Grease splines of stub shaft with grease - G 000 100- .
– Install right drive shaft ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Repairing drive shafts; Removing and installing drive
shaft .
– Install parts of exhaust system ⇒ Rep. gr. 26 ; Exhaust sys‐
tem .
– Check gear oil in bevel box ⇒ page 132 .
– Following installation, check oil level in gearbox
⇒ page 103 .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 50 ; Noise insulation .
Specified torques: ⇒ page 83
AG. Volkswagen AG d
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lksw not
10.3 Detaching bevel box from gearbox -
Vo gu
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gearbox removed
or eo
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Special tools and workshop equipment required
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Removing
rrectness of i
– Remove gearbox with bevel box ⇒ page 61 .
l purpos
nform
ercia
at
om
i
condition.
on
c
in t
or
his
ate
gearbox.
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
– Unscrew lower securing bolts -arrows- and remove bevel box.
rm
ab
pe
ility
Installing
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
Note yri
p by
co Vo
by lksw
cted agen
Prote
Turn stub shaft if spline position is unfavourable (bevel box cannot
AG.
Caution
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
– In order to ensure that the breather pipe of the adapter for oil
ility
ot p
filling - VAS 6262 A- does not contact the bottom of some oil
wit
, is n
h re
bottles, the pipe must be shortened to the length -a-.
hole
spec
Dimension -a- = 210 mm
es, in part or in w
t to the co
Note
rrectness of i
The dimension -a- is measured from the shaft (green area in the
l purpos
nform
ercia
– Mark dimension -a- on the breather pipe and shorten pipe with
m
at
pipe cutter - VAS 6056/2- .
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
The filter must be changed if:
itte
y li
erm
ab
♦ Coolant has got into the oil.
ility
ot p
wit
, is n
♦ Metal particles have been found in the oil.
h re
hole
♦ The clutch is burnt out or has a mechanical defect.
spec
es, in part or in w
t to the co
Note
rrectness of i
Refer to general repair instructions ⇒ page 6 .
l purpos
Removing
nf
ercia
orm
m
atio
– Remove air filter housing ⇒ Rep. gr. 24 ; Removing and in‐
om
n in
or c
thi
e
sd
iva
o
r
rp
cu
– Remove left coolant pipe together with charge air pipe ⇒ Rep.
o
m
f
en
ng
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectnes
♦ Used oil collector and extractor - V.A.G 1782-
s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Conditions
♦ Vehicle level, all mountings of lifting platform evenly at same
height
♦ Noise insulation removed agen
AG. Volkswagen AG d
oes
ol ksw not
♦ Vehicle diagnosis, testingedand
by V
information system - VAS gu
ara
5051B- is connected. horis nte
eo
ut ra
a
♦ At start of work, oilsstemperature must not be above 45°C. c
ce
e
nl
pt
du
an
itte
y li
Check
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Select Dual clutch gearbox .
es, in part or in w
t to the co
– Select Check oil level .
rrectness of i
Note
l purpos
nform
mercia
at
Engine is running at idling speed with selector lever in “P”.
om
ion
c
in t
– Remove oil drain plug -arrow-.
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Even if oil level is too low, a small amount of oil will initially run out
of oil level pipe because pipe fills up during operation.
– Before screwing adapter for oil filling - VAS 6262 A- onto oil
bottle, measure length of breather pipe, dimension -a- and
shorten ⇒ page 101 .
Dimension -a- = 210 mm
Note
The dimension -a- is measured from the shaft (green area in the
magnifying glass) of the adapter for oil filling - VAS 6262 A- .
WARNING
ce
e
– Pull off adapter for oil filling - VAS 6262- at plug-in connector
nl
pt
du
and check:
an
itte
y li
erm
ab
If oil now flows out of hole in adapter:
ility
ot p
wit
Oil does not need topping up.
, is n
h re
hole
spec
es, in part or in w
– When excess oil has run out (when it begins only to drip), re‐
t to the co
move adapter for filling oil - VAS 6262 A- and install plug with
new seal.
rrectness of i
If no oil drips out of inspection hole:
l purpos
nf
ercia
WARNING orm
m
atio
m
An oil level which is too low or too high will impair the function
o
n in
c
of the gearbox.
or
thi
te
sd
iva
o
r
rp
cu
o
en
ng
t.
yi Co
Cop py
t. rig
11.3 Draining and filling oil
gh ht
pyri by
Vo
o
by c lksw
cted
If DSG oil must be added, use only oil listed in ⇒ Electronic parts
agen
Prote AG.
catalogue “ETKA” .
Please also refer to the notes on the oil filter change regarding
»dirty oil« ⇒ page 101 .
Brief description
First read the oil temperature. If it is above 50°C, allow the gear‐
box to cool down.
With engine stopped, unscrew and remove overflow pipe and let
the oil drain out. Then reinstall overflow pipe and »overfill« gear‐
box with oil.
Then start engine and drain excess oil until oil level attains level
of overflow pipe.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
c
♦ Used oil collector and extractor - V.A.G 1782- ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Conditions
♦ Engine switched off
♦ Vehicle level, all mountings of lifting platform evenly at same
height
♦ Noise insulation removed if previously fitted
♦ Selector lever at “P”
♦ Vehicle diagnosis, testing and information system - VAS
5051B- is connected.
♦ At start of work, oil temperature must not be above 45 °C.
Procedure
– Comply with rules for cleanliness when working on gearbox
⇒ page 5 .
– Only gear oil available as spare part is allowed to be used for
dual clutch gearbox. Other oils will lead to malfunctions or fail‐
ure of the gearbox ⇒ Electronic Parts Catalogue (ETKA) .
WARNING
ce
le
– Select Dual clutch gearbox .
un
pt
an
d
itte
y li
– Select Check oil level .
erm
ab
ility
ot p
wit
Note is n
h re
ole,
spec
urposes, in part or in wh
t to the co
down.
rrectne
WARNING
ss
Do not start engine if there is no oil in gearbox.
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove oil level pipe -arrow- and allow oil to run out.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Remove oil drain plug -arrow- from mechatronic unit.
es, in part or in w
t to the co
Note
rrectness of i
A further approx. 1.2 litres of oil will run out.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
– Renew seal -arrow- and reinstall oil drain plug of mechatronic
fo
en
ng
– Before screwing adapter for oil filling - VAS 6262 A- onto oil
bottle, measure length of breather pipe, dimension -a- and
shorten ⇒ page 101 .
Dimension -a- = 210 mm
AG. Volkswagen AG d
agen oes
yV
olksw Note not
gu
d b ara
ise nte
r
The dimensionut -a- is measured from the shaft (green area in
ho e o the
ra
magnifying
s glass) of the adapter for oil filling - VAS 6262 A- . c
s a
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
WARNING
t to the co
Shake bottles thoroughly before opening to ensure that sedi‐
ment at the bottom of the bottle mixes well with the oil.
rrectnes
During filling, the adapter for oil filling - VAS 6262 A- and bottle
s o
cial p
f inform
mer
n
c
i
or
n thi
– Close tap on adapter when 5.5 litres of oil have been added
te
sd
va
to gearbox.
i
o
pr
cum
r
fo
– Start engine. The adapter for filling oil - VAS 6262 A- may re‐
en
ng
t.
yi
main connected.
Co
Cop py
ht. rig
ht
– Depress brake pedal and select each selector lever position
rig by
opy Vo
for about 3 seconds, then move lever back to »P« by c lksw
cted agen
Prote AG.
– Do NOT switch off engine.
– Then check oil level and top up. ⇒ page 103
AG. Volkswagen AG d
35 – Gears, shafts d by Volksw
agen oes
not
gu
ara
rise nte
ho eo
1 Currently, no repairs can be made to ut ra
s a c
s
gears and shafts
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
1.1 Assembly overview - bevel box
pt
an
d
itte
y li
rm
ab
pe
ility
1 - Outer left seal
ot
wit
, is n
h re
❑ Between bevel box and
hole
gearbox
spec
es, in part or in w
t to the co
box ⇒ page 87
❑ In case of leakage, also
renew »inner« seal
rrectness of i
⇒ Item 2 (page 111)
l purpos
nform
ercia
a
gearbox
com
tion in
❑ To renew, remove bevel
r
te o
thi
box ⇒ page 87
s
iva
do
r
cum
fo
en
ng
t.
yi
⇒ Item 1 (page 111)
Co
Cop py
t.
❑ Renewing ⇒ page 118
rig
gh ht
pyri by
Vo
co
3 - Bevel box
by lksw
cted agen
Prote AG.
❑ Removing and installing
⇒ page 87
4 - Seal
❑ Right (drive shaft side)
❑ Seal can be renewed
with bevel box installed
❑ Renewing ⇒ page 121
5 - Cap
❑ Right (drive shaft side),
if there is one
❑ Seal can be renewed
with bevel box installed
❑ Renewing ⇒ page 121
6 - Retaining ring
❑ Always renew
❑ Insert in circumferential groove in stub shaft
7 - O-ring
❑ Always renew
❑ Insert in circumferential groove in stub shaft
8 - Stub shaft
❑ To remove and install, remove bevel box ⇒ page 87
❑ Removing and installing ⇒ page 128
9 - Needle bearing (polygon bearing)
❑ Renewing ⇒ page 128
10 - Retaining ring
❑ Always renew
11 - Hexagon nut, 480 Nm
❑ Removing and installing ⇒ page 123
❑ Install using locking fluid - D 000 600-
12 - Output flange
❑ Removing and installing ⇒ page 123
n AG. Volkswagen AG do
wage es n
13 - Seal Vol
ks ot g
d by ua
❑ To renew, remove bevel box o⇒ris page 87
e ran
tee
th or
❑ Renewing ⇒ page 123 s a u ac
s
ce
le
14 - Bolt, 25 Nm
un
pt
an
d
y li
rm
ab
pe
15 - Pinion housing
ility
ot
wit
❑ With shaft bevel gear
, is n
h re
hole
spec
es, in part or in w
❑ Installing: place pinion housing loosely on bevel box, screw in all bolts by hand, screw in alternately until
t to the co
heads contact casing and then tighten bolts alternately
16 - O-ring
rrectness of i
❑ To renew, unscrew bolts ⇒ Item 14 (page 112) and carefully lever off pinion housing at projecting webs
on outside edge
l purpos
❑ Do not remove hexagon nut ⇒ Item 11 (page 112) and output flange ⇒ Item 12 (page 112)
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
❑ Renew
an
d
itte
y li
erm
ab
2 - Seal right, bevel box
ility
ot p
❑ Removing and installing
wit
is n
⇒ page 121
h re
ole,
spec
3 - Stub shaft
urposes, in part or in wh
t to the co
4 - Right oil seal, stub shaft
❑ Item can be disregarded
rrectne
5 - Output shaft seal
❑ Removing and installing
ss
⇒ page 123
o
cial p
f in
6 - Deflector ring
form
mer
atio
om
n
c
i
or
n thi
e
sd
iva
o
⇒ page 119
pr
cum
r
fo
en
ng
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
♦ Thrust piece - T10457-
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
Only drill through sheet metal ring (about 3 mm), otherwise bear‐
ing located behind it might be damaged.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
– Screw a self-tapping screw, approx. 4 mm in diameter, into
ce
le
un
pt
hole drilled in oil seal. Do not screw in sheet metal screw too
an
d
itte
y li
far to avoid damaging bearing behind it.
rm
ab
pe
ility
– Place drip tray for workshop hoist - VAS 6208- below gearbox.
ot
wit
, is n
T10055/2- .
spec
es, in part or in w
t to the co
Make sure no metal chips get into gearbox and into opening for
drive shaft. Vacuum out metal chips first if necessary.
– Carefully remove cloths and make sure that no metal chips get
rrectness of i
into gearbox.
l purpos
a
com
Installing
ion in
r
te o
the following:
do
r
rp
cum
fo
en
g
Before seal is installed, apply sealing grease for radial oil seal -
n
t.
yi Co
op
G 052 128 A1- to sealing lips and cavity, and apply ⇒ DSG oil to
C py
ht. rig
outer circumference. rig ht
py by
co Vo
by lksw
Installation position:
Prote
cted AG.
agen
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Removing
rrectness of i
Installing
orm
m
atio
n in
the following:
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Before seal is installed, apply sealing grease for radial oil seal -
G 052 128 A1- to sealing lips and cavity, and apply ⇒ DSG oil to
outer circumference.
Installation position:
Open side of oil seal faces gearbox.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
⇒ “4.1 Renewing seals on left (between bevel box and gearbox)”,
itte
y li
page 119
erm
ab
ility
ot p
⇒ “4.2 Renewing right seal (drive shaft side)”, page 121
wit
, is n
h re
⇒ “4.3 Renewing output flange oil seal (bevel box removed)”,
hole
spec
page 123
es, in part or in w
t to the co
⇒ “4.4 Renewing needle bearing (polygon bearing) for stub shaft”,
page 128
Special tools and workshop equipment required
rrectness of i
♦ Multi-purpose tool - VW 771- and multi-purpose tool - VW
l purpos
771/37-
♦ Extractor hook - T20143-
nf
ercia
orm
♦ Thrust piece - T10143-
m
atio
om
n in
c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
Removing
y li
rm
ab
pe
wit
, is n
spec
– Lever out seal using puller hook - T20143/2- .
es, in part or in w
t to the co
Note
l purpos
a
com
tion in
r
te o
thi
s
iva
do
r
rp
en
ng
t.
– Carefully use plastic mallet -2- to drive stub shaft out in direc‐
yi Co
op py
tion of arrow. t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Half-fill space between sealing lip and dust lip of new seal
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
i
– Drive in seal to stop.
on
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Half-fill space between sealing lip and dust lip of new seal
-arrow- with sealing grease - G 052 128 A1- .
– Lightly oil outer circumference of new oil seal.
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
t to the co
Note
rrectness of i
Removing
nform
ercia
– Raise vehicle.
m
at
om
ion
in t
or
do
riv
cum
or
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
Note py by
co Vo
by lksw
cted agen
Prote AG.
Some bevel boxes have protective cap -arrow- installed on right.
Renew protective cap each time after removing.
– Remove retaining ring -1- and seal -2- from stub shaft.
– Place drip tray under bevel box.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c ce
e
– Half-fill space between sealing lip and dust lip of new seal
nl
pt
du
an
-arrow- with sealing grease - G 052 128 A1- .
itte
y li
erm
ab
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
122
c by lksw
cted agen
Rep. gr.39 - Final drive - differential Prote AG.
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
pt
du
an
itte
box removed)
y li
erm
ab
ility
ot p
wit
, is n
Note h re
hole
spec
es, in part or in w
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
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– Coat thread of new hexagon nut with locking fluid D 000 600.
– Tightening new hexagon nut for output flange to specified tor‐
que.
Specified torque: ⇒ Item 11 (page 112)
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Special tools and workshop
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– Align both parts of tool so that marks “B” are opposite one
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– The shoulders -arrows- must then be below the bearing.
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– Install heat shield. Torque setting
oris ⇒ Running gear, axles,
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steering; Rep. gr. 40 ; Repairing
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drive shafts . ra
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– Install bevel box ⇒ page 87 .
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– Install noise insulation. ⇒ General body repairs, exterior; Rep. ility
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Rep. gr. 50 ; Noise insulation .
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– Top up gear oil if necessary ⇒ page 132 . Prote AG.
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5. Checking and topping up gear oil in bevel box
Sharan 2016 ➤ , Tiguan 2008 ➤
7-speed dual clutch gearbox 0BH - Edition 05.2017
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– Screw in »old« oil drain plug and tighten slightly.
– Start engine, engage gear and allow gearbox to turn for ap‐
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prox. 2 minutes.
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– Turn off engine and unscrew plug from oil filler hole.
– Check oil level, if necessary top up gear oil again to lower edge
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gr. 50 ; Noise insulation .