SKODA Fabia II 2007, Fabia II 2009, Fabia II 2011, Octavia II 2004, Octavia II 2010 Workshop Manual

Service

Workshop Manual

Fabia II 2007 ➤ , Fabia II 2009 ➤ ,

F
Octavia II 2010 ➤ , Rapid 2011 ➤ ,
Rapid India 2011 ➤ , Rapid NH 2013 ➤ ,
Rapid NH 2014 ➤ , Roomster 2006 ➤ ,
Superb II 2008 ➤ , Superb II 2011 ➤ ,

abia II 2011 ➤ , Octavia II 2004 ➤ ,

Yeti 2010 ➤ , Yeti 2011 ➤

Gearbox 0AM-DSG

Edition 01.2015

Service Department. Technical Information

Service

List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups

R

ep ai r Gr ou p

00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - differential

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...

Gearbox 0AM-DSG - Edition 01.2015

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Identification of the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2.1 Safety precautions when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 2

2.2 Safety precautions during road tests in which testing and measuring equipment is used . . 2

2.3 Safety measures for working on the mechatronics for double clutch gearbox J743 . . . . . . 2

3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.1 General points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.2 Explanation of the terms used in this workshop manual . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.3 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.4 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.5 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.6 Working with testing devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.7 Notes on tow starting and towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4.1 Filling capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4.2 Allocation gearbox - engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.3 Calculation of gear ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5 Overview of Transmission System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

6 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

6.1 Electric/electronic components and fitting locations of the automatic gearbox DSG - 0AM

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

1 Clutch operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

1.1 Assembly overview - clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

1.2 Removing and installing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1.3 Adjust clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

2 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

2.1 Summary of components - double clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

2.2 Remove double clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

2.3 Install double clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

2.4 Replacing the sealing ring for the outer drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

2.5 Replace gasket ring for inner drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

1 Mechatronics for double clutch gearbox J743 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

1.1 Summary of components - mechatronics for double clutch gearbox J743 . . . . . . . . . . . . 77

1.2 Remove mechatronics for double clutch gearbox J743 ; gearbox installed. . . . . . . . . . . . . 79

1.3 Bringing the mechatronics for double clutch gearbox J743 to the removal position by hand

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

1.4 Install mechatronics for double clutch gearbox J743 ; gearbox installed . . . . . . . . . . . . . . 89

2 Shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

2.1 Summary of components - Gearshift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

2.2 Inspecting the gearshift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

2.3 Inspecting and adjusting the selector lever control cable . . . . . . . . . . . . . . . . . . . . . . . . . . 105

2.4 Check the function of the ignition key removal lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

2.5 Removing and Installing the cover for the shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . 109

2.6 Removing and installing handle for shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

2.7 Installing the lock button at the selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

2.8 Removing and installing shift mechanism with selector lever control cable . . . . . . . . . . . . 118

Contents i

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Gearbox 0AM-DSG - Edition 01.2015

2.9 Removing and installing selector lever control cable, vehicles up to 05.2009 (Octavia II,

Superb II, Yeti) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

2.10 Emergency release of gearshift mechanism out of position P . . . . . . . . . . . . . . . . . . . . . . 127

2.11 Removing and installing the Tiptronic switch F189 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

2.12 Removing and installing selector lever lock solenoid N110 . . . . . . . . . . . . . . . . . . . . . . . . 130

2.13 Removing and installing selector lever switch locked in P F319 . . . . . . . . . . . . . . . . . . . . 130

2.14 Removing and installing the selector lever sensor control unit J587 . . . . . . . . . . . . . . . . . . 130

2.15 Checking the plug connections at the shift mechanism (Octavia II, Superb II, Yeti) . . . . . . 131

3 Removing and installing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

3.1 Removing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

3.2 Installing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

3.3 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

4 Transport the gearbox and secure to the assembly support . . . . . . . . . . . . . . . . . . . . . . . . 172

5 Change gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

1 Pinions and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

1 Replace gasket rings for rigid shafts and flange shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

1.1 Summary of components - gasket rings and output shafts . . . . . . . . . . . . . . . . . . . . . . . . 178

1.2 Replacing gasket ring for left rigid shaft (Octavia II, Superb II, Yeti) . . . . . . . . . . . . . . . . . . 179

1.3 Replacing gasket ring for right rigid shaft (Octavia II, Superb II, Yeti) . . . . . . . . . . . . . . . . 182

1.4 Replacing the left flange shaft gasket ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

1.5 Replacing the right flange shaft seal ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

ii Contents

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...

00 – Technical data

1 Identification

(SRL000769; Edition 01.2015)

⇒ “1.1 Identification of the gearbox”, page 1

1.1 Identification of the gearbox

Location of identification code letters on the gearbox
Example for a gearbox:
The gearbox code letter -arrow- is located at the top and bottom

of the gearbox.
♦ KHP = gearbox identification character
♦ 15.01.08 = Production date 15th January 2008
♦ 14 = Factory code
♦ 09:49 = time
♦ 0042 = serial number
The gearbox identification characters also appear on the vehicle

data stickers.

Gearbox 0AM-DSG - Edition 01.2015

Note

If these vehicle data stickers are not present and another gearbox
is installed than the one intended or you have no other possibility
to identify the installed gearbox in case of doubt, then read off the
identification characters directly from the gearbox.

1. Identification 1

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...
Gearbox 0AM-DSG - Edition 01.2015

2 Safety instructions

⇒ “2.1 Safety precautions when working on vehicles with a start/
stop system”, page 2

⇒ “2.2 Safety precautions during road tests in which testing and
measuring equipment is used”, page 2

⇒ “2.3 Safety measures for working on the mechatronics for dou‐
ble clutch gearbox J743 ”, page 2

2.1 Safety precautions when working on ve‐
hicles with a start/stop system

WARNING

On vehicles with start-stop system, there is the risk of injury
from automatic engine start.

♦ Deactivate the start-stop system when working on the ve‐

hicle. Switch off ignition.

♦ If required switch on the ignition for a short period of time.

2.2 Safety precautions during road tests in which testing and measuring equipment is used

If test and measuring devices are required during test drives, ob‐
serve the following information:

WARNING

There is a risk of accident from unintended motion and insuf‐
ficient securing of testers and measuring instruments.

There is a risk of injury from the release of the passenger air‐
bag in the event of an accident.

• Operation of test and measuring instruments by the driver
while driving may result in deviating from the direction of
travel.

• There is an increased risk of injury or accident from un‐
secured testers and measuring instruments.

♦ Fasten test and measurement equipment with a strap on

the rear seat and secure their operation by another person
sitting on the rear seat.

2.3 Safety measures for working on the mechatronics for double clutch gearbox

- J743-

DANGER!

Do not remove the pressure tank. The pressure tank is under
pressure and should not be opened.

2 Rep. gr.00 - Technical data

Caution

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...

Gearbox 0AM-DSG - Edition 01.2015

2. Safety instructions 3

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...
Gearbox 0AM-DSG - Edition 01.2015

3 Repair instructions

⇒ “3.1 General points”, page 4
⇒ “3.2 Explanation of the terms used in this workshop manual”,

page 7
⇒ “3.3 Contact corrosion”, page 9
⇒ “3.4 Gaskets and seals”, page 9
⇒ “3.5 Nuts and bolts”, page 9
⇒ “3.6 Working with testing devices”, page 10
⇒ “3.7 Notes on tow starting and towing”, page 11

3.1 General points

The automatic gearbox DSG°-°0AM is also designated as double
clutch gearbox.

The gearbox is built like a 7-speed manual gearbox.
Information on structure and function of the gearbox ⇒ Self-study

programme No. 75 ; automatic gearbox DSG - 0AM .
To ensure flawless and successful gearbox repairs, the greatest

care and cleanliness as well as the use of good and proper tools
are essential. Also note the basic rules on safety when performing
repair procedures.

A number of generally valid notes for individual repair operations

- which are otherwise listed several times at numerous points in
the workshop manual - are summarised here.

Notes apply to this particular workshop manual.
Special tools
List of the special tools used in the workshop manual is detailed

in the individual repair descriptions.
Summary of components of gearbox for vehicles Octavia II, Su‐

perb II and Yeti
1 - Ventilation cap of the gearbox
2 - Screw cap
3 - Gearshift lever
4 - Ventilation cap of the mechatronics for double clutch gear‐

box - J743­5 - Mechatronics for double clutch gearbox - J743­6 - Double clutch
7 - Up to production date “11.2008” rigid shaft, from production

date “11.2008” flange shaft ⇒ page 5
8 - Oil drain plug
9 - Automatic Gearbox DSG - 0AM

4 Rep. gr.00 - Technical data

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Gearbox with different output shafts
♦ -A- - Rigid shafts up to 11.2008
♦ -B- - Flange shafts as of 11.2008

Summary of components of gearbox for vehicles Fabia II, Room‐
ster, Rapid NH and Rapid India

1 - Ventilation cap of the gearbox
2 - Screw cap
3 - Gearshift lever
4 - Ventilation cap of the mechatronics for double clutch gear‐

box - J743­5 - Mechatronics for double clutch gearbox - J743­6 - Double clutch
7 - Flange shaft
8 - Oil drain plug
9 - Automatic Gearbox DSG - 0AM
Continued for all vehicles
Gearbox

Gearbox 0AM-DSG - Edition 01.2015

3. Repair instructions 5

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...
Gearbox 0AM-DSG - Edition 01.2015

The gearbox has an opening in the housing -arrow-.
Vehicles Octavia II, Superb II and Yeti

Note

♦

When installing pay attention that nothing falls into this open‐
ing.

♦

Cover the opening with a cloth before commencing installation
work.

For vehicles Fabia II, Roomster and Rapid NH

Note

♦

This opening is closed with a cap.

♦

When installing pay attention that nothing falls into this open‐
ing.

Continued for all vehicles
♦ If the covers are unscrewed from the gearbox or the gearbox

is without oil, do not let the engine run and do not tow the ve‐
hicle.

♦ Permanently ensure that no dirt can get into the opened gear‐

box.

♦ Thoroughly clean the connection points and their surroundings

and then release.

♦ When installing the gearbox, ensure the dowel sleeves are

correctly located between the engine and gearbox.

On some transmissions, a cover is present above the engaging
lever.

The cover protects against contamination.

Tightening torque securing bolts: 8 Nm
Mechatronics
♦ The mechatronics is allocated according to the gearbox code

letters ⇒ Electronic Catalogue of Original Parts .
♦ The new mechatronics for the gearbox is already precisely fil‐

led with oil at the factory, do not drain the oil.
♦ The removed mechatronics for the gearbox is sent back with

oil (close the ventilation opening with a suitable plug).
♦ During assembly work, remove the cover of the ventilation for

the mechatronics and close the opening with a suitable screw

plug. In case of oil leakage from the mechatronics , the me‐

chatronics must be replaced.
Gear oil

6 Rep. gr.00 - Technical data

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The “7-speed double clutch gearbox DSG - 0AM” has two sepa‐
rate, different oil fillings. One for the area with gearbox oil

-arrow A- and the other one for the area with hydraulic oil

-arrow B-.
The oil level cannot be checked. The correct gear oil level can

only be achieved by changing the gear oil, for example if the
gearbox leaks ⇒ “5 Change gearbox oil”, page 174 .

Caution

Be careful when handling oil. Dispose of drained oil appropri‐
ately.

♦ Shake oil bottle before opening.
♦ Do not mix any additives in the oil, also do not fill in other oil.
♦ Drained oil must not be reused.
Locking elements
♦ Do not over-extend the circlips, if necessary replace.
♦ Circlips must be positioned in the base of the groove.
Electrical components
If you touch objects out of metal, it can happen that this can lead

to an electrostatic discharge. This is due to the electrostatic
charge accumulated by the human body. This electrostatic
charge can lead to operational problems when touching the elec‐
trical components of the gearbox and the shift mechanism.

– Touch an earthed object, e. g. a metal pipe or a lift platform,

before working on the electrical components.
– Do not grab directly at the plug contacts.
Targeted fault-finding
Before repairing the gearbox try to determine the origin of the

damage as accurately as possible using “targeted fault finding”.

Gearbox 0AM-DSG - Edition 01.2015

The “targeted fault finding” is performed with the ⇒ Vehicle diag‐
nostic tester.

Rules of cleanliness
♦ Thoroughly clean the connection points and their surroundings

before releasing.
♦ Only install clean parts: Remove spare parts from their wrap‐

ping immediately before fitting.
♦ Always replace the paper gaskets. Completely remove old

gasket and thoroughly clean sealing surfaces.
♦ Place removed parts on a clean surface and cover them to

prevent them from getting dirty. Use sheeting and paper for

this purpose. Do not use fuzzy cloths!
♦ Carefully cover or close opened components if the repair is not

completed immediately.

3.2 Explanation of the terms used in this

workshop manual

These explanations are only related to the automatic gearbox
DSG - 0AM. They do not claim to be valid in all cases.

3. Repair instructions 7

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Gearbox 0AM-DSG - Edition 01.2015

CAN databus
Data transfer. Before transmission, electrical signals are put into

certain forms (BUS). Further information on this can be found in
⇒ Self-study programme No. 24 ; Škoda OCTAVIA; CAN data‐
bus; Structure and Function .

DSG
Automatic gearbox DSG. Further information can be found in

⇒ Self-study programme No. 75 ; Automatic gearbox DSG ­0AM .

Self-diagnosis
The capability of the control unit to:
– Detect faults.
– React to faults.
– Store faults.
– Determine measured values and display them in the meas‐

ured value block.
Gearbox input r.p.m. sender - G182­The sender determines the speed at the clutch and sends it to the

mechatronics.
Gearbox
The automatic gearbox DSG°-°0AM is also designated as double

clutch gearbox. The engine torque is initiated in the gearbox via
the two-mass flywheel. The flywheel and the double clutch are
interconnected via a serration. The gearbox is built like a 7-speed
double clutch gearbox OAM. Due to the alternative hydraulic ac‐
tivation of the two dry clutches, it is operated like an automatic
gearbox, i.e. the gears are automatically or manually engaged via
the Tiptronic mode. A clutch pedal is not present.

Gear oil
The gearbox has separate oil fillings for mechatronics and manual

gearboxes. Oils are designed to be filled for life.
Selector lever lock solenoid - N110­The selector lever lock solenoid is integrated into the shift mech‐

anism. Prevents (unintentional) tipping of the selector lever from
the positions P and N when the brake is not operated.

Emergency running mode
If individual or several components or sensors fail, the gearbox

control unit activates the corresponding backup functions or
emergency running programmes. This ensures a nondestructive
operation of the gearbox with the respective effect on the function
and quality of the shifting.

The emergency running mode is a status of the control unit,
which, if a fault of the control unit is detected, maintains driving
safety, protects the gearbox from damage, and ensures that ve‐
hicle running will be affected as little as possible.

Parking position
When the vehicle is parked, the selector lever mechanically locks

the parking gear thereby preventing the vehicle from moving off
unintentionally.

Shift mechanism
The selector lever position is no longer communicated mechani‐

cally, as for the other automatic gearboxes, via the selector lever
control cable and the multi-function switch (sensor for driving po‐

8 Rep. gr.00 - Technical data

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sition) to the gearbox. The selector lever positions or shifting are
transmitted via a separate control unit in the shift mechanism via
the CAN databus to the mechatronics. The shifting is then per‐
formed without control cable. Only in the selector lever position P
is the parking position engaged mechanically via the selector lev‐
er control cable.

Gear-change points change on upward and downward gradients
On upward or downward gradients, gear-changes are selected

automatically by additional gear-change mapping, according to
accelerator position and driving speed.

♦ On steep gradients, gear-change mapping is adapted to en‐

gine power output.

♦ On steep gradients, gear-change mapping is adapted to the

braking effect of the engine.

♦ By directly selecting a gear via the Tiptronic, it is also possible

to use engine braking with a specific gear, e.g. for a slope

during trailer operation.
Tiptronic
Another one exists to the right of the normal selector lever gate.

In this selector lever gate, the selector lever can be tipped towards
the Plus sign (+) to change up the gears manually and vice versa
towards the Minus sign (-) to change down the gears manually.

Gearbox 0AM-DSG - Edition 01.2015

3.3 Contact corrosion

The gearbox housing and the clutch housing are made out of
magnesium alloy.

Bolts and other components that come into direct contact with the
gearbox have a surface with varying finishes in relation to it.

The use of substitute components causes contact corrosion
(screws. nuts. washers ...). The gearbox housing and the clutch
housing are damaged.

Generally install parts which are indicated in the ⇒ Electronic
Catalogue of Original Parts .

3.4 Gaskets and seals

♦ After removing all seals, inspect the contact faces on housings

and shafts for burrs and damage and remove all which are

found.
♦ Before a radial shaft seal is installed, coat the sealing lips and

the space in-between halfways with sealing grease - G 052

128 A1- .
♦ The open side of the sealing rings is assembled towards the

oil.
♦ Always replace O-rings, gasket rings and gaskets ⇒ Elec‐

tronic Catalogue of Original Parts .
♦ Before inserting the O-rings only coat with DSG oil to prevent

the rings being damaged during installation. A different lubri‐

cant can cause functional faults.
♦ After installing, check gear oil level

⇒ “5 Change gearbox oil”, page 174 .

3.5 Nuts and bolts

♦ Slacken and tighten screws or fixing nuts of covers and hous‐

ings diagonally across in stages.

3. Repair instructions 9

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...
Gearbox 0AM-DSG - Edition 01.2015

♦ Specified torques given are for unlubricated nuts, bolts and

screws.

♦ Clean the thread of the screws that are inserted with a locking

agent with a wire brush. Insert bolts with locking agent - AMV
185 101 A1- .

♦ Clean all threaded holes into which bolts are screwed in with

locking agent, using a thread tap to remove locking agent res‐
idues. Otherwise there is a danger of bolts shearing when
subsequently being removed.

♦ Always replace the self-locking screws and nuts.

3.6 Working with testing devices

♦ Vehicle diagnosis, measurement and information system -

VAS/ODIS-

Work in the operating modes targeted functions and tar-

geted fault finding.

Adapt information regarding lining
The mechatronics detects the other control units in the vehicle via

the signals in the CAN bus. If the button adapt information

regarding lining is pressed, the mechatronics receives a

command to forget all systems with which it can communicate.
However, after switching on the ignition all active systems with

which it can communicate are detected.
No faults can be generated with this function. The function adapt

information regarding lining is always carried out after the

following operations:
♦ After installing the mechatronics.
♦ After the gearbox has been fitted.
♦ After installing the selector lever.
♦ After installing another control unit, for example the engine

control unit, the ABS control unit or the diagnostic interface for

data bus (Gateway).
Vehicles Octavia II, Superb II and Yeti
♦ After working on the steering column gearshift.
Perform basic setting
The mechatronics memorises important settings in the function

COMPLETE BASIC SETTING. The important settings are also

memorised, e.g reset to preprogrammed points. For example, the
synchronisation points and the vertices for the engaging lever and
gear switches.

– Button COMPLETE BASIC SETTING only functions:
♦ after interrogating with “Targeted fault finding”,

♦ after rectifying the fault stored in the event memory,
♦ after installing the clutch,
♦ or after installing the Mechatronics.

10 Rep. gr.00 - Technical data

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...

3.7 Notes on tow starting and towing

Caution

When towing the vehicle, the selector lever must be in position
N and it must not be towed further than 50 km and faster than
50 km/h, otherwise the gearbox will be destroyed.

It is not possible to tow start an engine, e.g. if the battery is
weak or the starter does not operate.

Gearbox 0AM-DSG - Edition 01.2015

3. Repair instructions 11

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...
Gearbox 0AM-DSG - Edition 01.2015

4 Technical data

⇒ “4.1 Filling capacity”, page 12
⇒ “4.2 Allocation gearbox - engine”, page 13
⇒ “4.3 Calculation of gear ratios”, page 21

4.1 Filling capacity

The 7-speed double clutch gearbox DSG - 0AM has two separate,
different oil fillings. One for the area with gearbox oil -arrow A­and the other one for the area with hydraulic oil -arrow B-.

Gearbox capacity Area with gearbox oil
New filling 1.9 l

Top-up no top-up
Lubricant Gearbox oil for double clutch gearbox 0AM

part number ⇒ Electronic Catalogue of Original Parts

The gear oil filling is permanent for the 7-speed double clutch
gearbox 0AM (oils are designed to be filled for life). For this reason
the oil level is not checked and the inspection plug is not present
on this gearbox.

Capacity in the mechatronics for
double clutch gearbox - J743-

Filling 1 ltr.
Top-up no top-up
♦ The mechatronics is allocated according to the gearbox code letters ⇒ Electronic Catalogue of Original

Parts .

♦ The new mechatronics for the gearbox is already precisely filled with oil at the factory.

Area with hydraulic oil

12 Rep. gr.00 - Technical data

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...

Caution

Only spare part gear oils should be used for the 7-speed double
clutch gearbox DSG - 0AM.

Other oils can lead to functional problems or to failure of the
gearbox.

4.2 Allocation gearbox - engine

⇒ “4.2.1 Identification characters, aggregate assignment, ratios
(Octavia II)”, page 13

⇒ “4.2.2 Identification characters, aggregate assignment, ratios
(Superb II)”, page 15

⇒ “4.2.3 Identification characters, aggregate assignment, ratios
(Yeti)”, page 17

⇒ “4.2.4 Identification characters, aggregate assignment, ratios
(Fabia II)”, page 18

⇒ “4.2.5 Identification characters, aggregate assignment, ratios
(Roomster)”, page 19

⇒ “4.2.6 Identification characters, aggregate assignment, ratios
(Rapid NH)”, page 20

⇒ “4.2.7 Identification characters, aggregate assignment, ratios
(Rapid India)”, page 20

Gearbox 0AM-DSG - Edition 01.2015

4.2.1 Identification characters, aggregate assignment, ratios (Octavia II)

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

ters

Assignment Engine 1.8 ltr./118 kW TFSI 1.8 ltr./118 kW TFSI

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

Assignment Engine 1.8 ltr./118 kW TFSI

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

Assignment Engine 1.8 ltr./118 kW TFSI

Manufactured from

throug

h

ters
Manufactured from

throug

h

ters
Manufactured from

throug

h

LKN LPK LSS

11.2008

05.2009

MGL MLC MPJ

11.2009

05.2010

NAT NQB NTQ

06.2011

10.2011

05.2009

05.2009

06.2010

10.2010

1.8 ltr./112 kW TFSI

11.2011

05.2012

1.8 ltr./112 kW TFSI

06.2009

10.2009

1.8 ltr./112 kW TFSI

11.2010

05.2011

06.2012

10.2012

4. Technical data 13

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...
Gearbox 0AM-DSG - Edition 01.2015

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

ters

Assignment Engine 1.8 ltr./118 kW TFSI

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

Assignment Engine 1.4 ltr./90 kW TSI

Manufactured from

throug

h

ters
Manufactured from

throug

h

PMJ

11.2012

04.2013

1.8 ltr./112 kW TFSI

KHN LKG LKM

11.2008

11.2008

11.2008

11.2008

11.2008

05.2009

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

ters

Assignment Engine 1.4 ltr./90 kW TSI

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

Assignment Engine 1.4 ltr./90 kW TSI

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

Assignment Engine 1.4 ltr./90 kW TSI

Manufactured from

throug

h

ters
Manufactured from

throug

h

ters
Manufactured from

throug

h

LPJ LWZ MGK

05.2009

05.2009

MLB MPH NAS

06.2010

10.2010

NBA NQK NTZ

06.2011

10.2011

06.2009

10.2009

11.2010

05.2011

11.2011

05.2012

11.2009

05.2010

05.2011

05.2011

06.2012

11.2012

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

ters
Manufactured from

throug

h

MGU MLJ MPQ

02.2010

05.2010

06.2010

10.2010

14 Rep. gr.00 - Technical data

11.2010

05.2011

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...

Gearbox 0AM-DSG - Edition 01.2015

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

ters

Assignment

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

Assignment Engine 1.2 ltr./77 kW TSI

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

Assignment Engine 1.6 ltr./77 kW TDI CR

Engine 1.2 ltr./77 kW TSI

ters
Manufactured from

throug

h

ters
Manufactured from

throug

h

MGU MLJ MPQ

NBA NQK NTZ

06.2011

10.2011

MGN MLE MPL

11.2009

05.2010

11.2011

05.2012

06.2010

10.2010

06.2012

11.2012

11.2010

05.2011

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

ters

Assignment Engine 1.6 ltr./77 kW TDI CR

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

Assignment Engine 1.6 ltr./77 kW TDI CR

Manufactured from

throug

h

ters
Manufactured from

throug

h

NKA NQE NTT

06.2011

10.2011

PML

11.2012

04.2013

11.2011

05.2012

06.2012

10.2012

4.2.2 Identification characters, aggregate assignment, ratios (Superb II)

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

ters

Assignment Engine 1.8 ltr./118 kW TFSI 1.8 ltr./112 kW TFSI

Manufactured from

throug

h

KHP LKN LKN

09.2008

10.2008

11.2008

05.2009

03.2009

05.2009

4. Technical data 15

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...
Gearbox 0AM-DSG - Edition 01.2015

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

ters

Assignment Engine 1.8 ltr./118 kW TFSI

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

Assignment Engine 1.8 ltr./118 kW TFSI

Manufactured from

throug

h

ters
Manufactured from

throug

h

LPK LSS MGL

05.2009

05.2009

MLC MPJ NAT

06.2010

10.2010

06.2009

10.2009

1.8 ltr./112 kW TFSI

11.2010

05.2011

1.8 ltr./112 kW TFSI

11.2009

05.2010

06.2011

11.2011

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

ters

Assignment Engine 1.8 ltr./118 kW TFSI

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

Assignment Engine 1.8 ltr./118 kW

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Engine code PVV PVW

Assignment Engine 1.8 ltr./118 kW TFSI 1.6 ltr./77 kW TDI CR

Manufactured from

throug

h

ters
Manufactured from

throug

h

Manufactured fr

o
m
to

NQB NTQ PMJ

11.2011

05.2012

1.8 ltr./112 kW TFSI

PKN PKQ PKP

06.2013

10.2013

TFSI

11.2013

05.2014

06.2012

10.2012

1.8 ltr./118 kW TFSI

06.2013

06.2013

1.6 ltr./77 kW TDI CR

11.2013

05.2014

11.2012

05.2013

06.2013

10.2013

16 Rep. gr.00 - Technical data

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...

Gearbox 0AM-DSG - Edition 01.2015

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification

characters

Assignment Engine 1.8 ltr./118 kW TFSI 1.6 ltr./77 kW TDI CR

Manufac‐
tured

f
r
o
m
t
o

QQU QGV QQV QGX

05.2014

11.2014

11.2014 05.2014

11.2014

11.2014

4.2.3 Identification characters, aggregate assignment, ratios (Yeti)

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

ters

Assignment Engine 1.2 ltr./77 kW TFSI

Manufactured from

throug

h

MGU MLJ MPQ

02.2010

05.2010

06.2010

10.2010

11.2010

05.2011

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

ters

Assignment Engine 1.2 ltr./77 kW TFSI

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

Assignment Engine 1.2 ltr./77 kW TFSI 1.4 ltr./90 kW TSI

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Engine code PWD

Assignment Engine 1.2 ltr./77 kW TFSI 1.4 ltr./90 kW TSI

Manufactured from

throug

h

ters
Manufactured from

throug

h

Manufactured from

NBA NQK NTZ

06.2011

10.2011

PMS PKW

11.2012

05.2013

to

11.2013

05.2014

11.2011

05.2012

01.2013

05.2013

06.2012

10.2012

06.2013

10.2013

11.2013

05.2014

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification characters QRB QHE

Manufactured from

to

05.2014

11.2014

11.2014

4. Technical data 17

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...
Gearbox 0AM-DSG - Edition 01.2015

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification characters QRB QHE
Assignment

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

Assignment Engine 1.6 ltr./77 kW TDI CR

Engine 1.2 ltr./77 kW TFSI

1.4 ltr./90 kW TSI

PVW QQV QGX

ters
Manufactured from

to

11.2013

05.2014

05.2014

11.2014

11.2014

4.2.4 Identification characters, aggregate assignment, ratios (Fabia II)

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

ters

Assignment Engine 1.2 ltr./77 kW TFSI

Manufactured from

throug

h

MGV MLN MPU

03.2010

05.2010

05.2010

10.2010

11.2010

05.2011

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

ters

Assignment Engine 1.2 ltr./77 kW TFSI

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

Assignment Engine 1.2 ltr./77 kW TFSI

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

Assignment Engine 1.4 ltr./132 kW TFSI

Manufactured from

throug

h

ters
Manufactured from

throug

h

ters
Manufactured from

throug

h

NBD NQN NUC

06.11

10.2011

PMV PKZ PWG

11.2012

05.2012

MLH MPP NAY

05.2010

10.2010

11.2011

05.2012

06.2013

10.2013

11.2010

05.2011

06.2012

10.2012

11.2013

05.2014

06.2011

10.2011

18 Rep. gr.00 - Technical data

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...

Gearbox 0AM-DSG - Edition 01.2015

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

ters

Assignment Engine 1.4 ltr./132 kW TFSI

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

Assignment Engine 1.4 ltr./132 kW TFSI

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

Assignment Engine 1.4 ltr./132 kW TFSI

Manufactured from

throug

h

ters
Manufactured from

throug

h

ters
Manufactured from

to

MLH MPP NAY

05.2010

10.2010

NQH NTW PMP

11.2011

05.2012

PKT PWA QQY

05.2013

11.2013

11.2010

05.2011

06.2012

10.2012

11.2013

05.2014

06.2011

10.2011

11.2012

05.2013

05.2014

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

ters

Assignment Engine 1.2 ltr./77 kW TFSI

Manufactured from

throug

h

QRE QHH

05.2014

11.2014

11.2014

4.2.5 Identification characters, aggregate assignment, ratios (Roomster)

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

ters

Assignment Engine 1.2 ltr./77 kW TFSI

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

Assignment Engine 1.2 ltr./77 kW TFSI

Manufactured from

throug

h

ters
Manufactured from

throug

h

MGV MLN MPU

03.2010

05.2010

NBD NQN NUC

06.2011

10.2011

05.2010

10.2010

11.2011

05.2012

11.2010

05.2011

06.2012

10.2012

4. Technical data 19

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...
Gearbox 0AM-DSG - Edition 01.2015

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

ters

Assignment Engine 1.2 ltr./77 kW TFSI

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

Assignment Engine 1.2 ltr./77 kW TFSI

Manufactured from

throug

h

ters
Manufactured from

throug

h

PMV PKZ PWG

11.2012

05.2012

QRE QHH

05.2014

11.2014

06.2013

10.2013

11.2014

11.2013

05.2014

4.2.6 Identification characters, aggregate assignment, ratios (Rapid NH)

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

ters

Assignment Engine 1.4 ltr./90 kW TSI

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Engine code PWE QRC QHF

Assignment Engine 1.4 ltr./90 kW TSI

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification

Assignment Engine 1.6 ltr./66 kW TDI CR

Manufactured from

Manufactured from

characters
Manufac‐

tured

from

to

throug

h

to

PKY PWF QRD QHD

08.2013

10.2013

NUA PMT PKX

11.2012

11.2012

11.2013

05.2014

11.2013

05.2014

11.2012

05.2013

05.2014

11.2014

05.2014

11.2014

06.2013

10.2013

11.2014

11.2014

4.2.7 Identification characters, aggregate assignment, ratios (Rapid India)

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

ters
Manufactured from

throug

h

PWF QRD QHG

09.2014

09.2014

09.2014

01.2015

01.2015

20 Rep. gr.00 - Technical data

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...

Gearbox 0AM-DSG - Edition 01.2015

Automatic gearbox DSG 0AM - front-wheel drive
Gearbox Identification charac‐

PWF QRD QHG

ters

Assignment

Engine 1.5 l/77 kW TDI CR

4.3 Calculation of gear ratios

Example:

5. gear Final drive
Drive gear ZG1 = 46 ZA1 = 24
Driven gear ZG2 = 33 ZA2 = 70

i = ZG2 : ZG1

1)

iG = Gear ratio = ZG2: ZG1 = 33 : 46 = 0,717

iA = Ratio of the final drive = ZA2 : ZA1 = 70 : 24 = 2,917

i

= Total ratio = iG × iA = 0.717 × 2.917 = 2.091

total

1) Z1 = No. of teeth on driving gear, Z2 = No. of teeth on driven gear

4. Technical data 21

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...
Gearbox 0AM-DSG - Edition 01.2015

5 Overview of Transmission System

The 7-speed double clutch gearbox DSG - 0AM has 2 drive shafts
and 3 output shafts.

A1 - 1. Drive shaft
A2 - 2. Drive shaft
B1 - 1. Output shaft
B2 - 2. Output shaft
B3 - 3. Output shaft
C - Front final drive
K1 - Clutch 1
K2 - Clutch 2
M - Engine
T1 - One part of the gearbox 1

❑ with 1st, 3rd, 5th and 7th

gear

T2 - One part of the gearbox 2

❑ with 2nd, 4th, 6th gear

and reverse gear R

22 Rep. gr.00 - Technical data

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...

Gearbox 0AM-DSG - Edition 01.2015

6 Electrical components

⇒ “6.1 Electric/electronic components and fitting locations of the
automatic gearbox DSG - 0AM”, page 23

6.1 Electric/electronic components and fit‐
ting locations of the automatic gearbox
DSG - 0AM

⇒ “6.1.1 Electric/electronic components and fitting locations of the
automatic gearbox DSG - 0AM (Octavia II, Superb II and Yeti)”,
page 23

⇒ “6.1.2 Electric/electronic components and fitting locations of the
automatic gearbox DSG - 0AM (Fabia II and Roomster)”,
page 26

⇒ “6.1.3 Electric/electronic components and fitting locations of the
automatic gearbox DSG - 0AM (Rapid)”, page 29

6.1.1 Electric/electronic components and fitting locations of the automatic gear‐
box DSG - 0AM (Octavia II, Superb II and Yeti)

1 - Diagnostic connection

❑ Fitting location: under

the cover in the driver's
footwell

2 - Selector lever position indi‐
cator - Y6-

❑ Fitting location: Integra‐

ted in the dash panel in‐
sert

❑ a switched off gear dis‐

play points to an emer‐
gency operation with
deactivated gearbox
control unit

❑ a fully lit gear display

points to an emergency
operation with activated
gearbox control unit

❑ can only be replaced to‐

gether with the dash
panel insert ⇒ Electrical
System; Rep. gr. 90

3 - Cover for shift mechanism
with lamp for selector lever
scale illumination - L101-

❑ the lamp for selector lev‐

er scale illumination ­L101- is integrated in
the cover frame; fitting
location ⇒ page 25

❑ the lamp for selector lev‐

er scale illumination ­L101- is checked by
self-diagnosis

❑ as of 11.2012 (CW 45),

the selector lever han‐
dle was changed

⇒ “2.1 Summary of components - Gearshift mechanism”, page 97

6. Electrical components 23

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...
Gearbox 0AM-DSG - Edition 01.2015

❑ Removing and installing ⇒ “2.5 Removing and Installing the cover for the shift mechanism”, page 109

4 - Gearbox input r.p.m. sender - G182-

❑ Fitting location ⇒ page 25
❑ is checked by self-diagnosis
❑ is a component and can only be removed and installed with the° mechatronics for double clutch gearbox

- J743- ⇒ “1 Mechatronics for double clutch gearbox J743 ”, page 77

5 - Mechatronics for double clutch gearbox - J743-

❑ Fitting location ⇒ page 24
❑ is checked by self-diagnosis
❑ Removing and installing ⇒ “1 Mechatronics for double clutch gearbox J743 ”, page 77

6 - Selector lever lock solenoid - N110-

❑ Fitting location ⇒ page 25
❑ is checked by self-diagnosis

7 - Selector lever - E313- with Tiptronic switch - F189- , selector lever sensor control unit - J587- and selector
lever switch locked in P - F319-

❑ Fitting location ⇒ page 25
❑ is checked by self-diagnosis
❑ Tiptronic switch - F189- , selector lever sensor control unit - J587- and selector lever switch locked in P

- F319 - are integrated into the shift mechanism.

❑ these components cannot be replaced separately; the removal and installation procedure is only possible

together with the gearshift mechanism

⇒ “2.8 Removing and installing shift mechanism with selector lever control cable”, page 118

8 - Brake light switch - F- and brake pedal switch - F47-

❑ Fitting location ⇒ page 26
❑ Signal transfer from engine control unit to gearbox control unit via CAN databus
❑ is checked by self-diagnosis
❑ removing and installing ⇒ Chassis; Rep. gr. 46

9 - Kick-down switch - F8-

❑ Fitting location ⇒ page 26
❑ Signal transfer from engine control unit to gearbox control unit via CAN databus
❑ is checked by self-diagnosis
❑ Removing and Installing ⇒ Engine; Rep. gr. 20

Mechatronics for double clutch gearbox - J743­Fitting location: The mechatronics for double clutch gearboxes -

J743- is screwed onto the front gearbox housing.
The control unit is firmly integrated in the mechatronics for double

clutch gearbox - J743- .
The senders and the actuators are located in the mechatronics

for double clutch gearbox - J743- . Further information can be
found in ⇒ Self-study programme No. 75 ; Automatic gearbox
DSG - 0AM .

Removing and installing the mechatronics for double clutch gear‐
box - J743-

⇒ “1 Mechatronics for double clutch gearbox J743 ”, page 77 .

24 Rep. gr.00 - Technical data

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...

Gearbox input r.p.m. sender - G182­Fitting location: The gearbox input speed sender - G182- is clip‐

ped onto the front of the gearbox housing. Release the sender for
removal and pull out in -direction of arrow-.

The gearbox input r.p.m. sender - G182- can only be replaced
together with the mechatronics for double clutch gearbox - J743-

⇒ “1 Mechatronics for double clutch gearbox J743 ”, page 77 .

Selector lever lock solenoid - N110­The selector lever lock solenoid - N110- fitting location -arrow- is

located in the gearshift mechanism

⇒ “2.1 Summary of components - Gearshift mechanism”,
page 97 .

The selector lever lock solenoid - N110- is installed firmly in the
gearshift mechanism and cannot be replaced individually. The
removal and installation procedure is only possible together with
the gearshift mechanism

⇒ “2.8 Removing and installing shift mechanism with selector lev‐
er control cable”, page 118 .

Gearbox 0AM-DSG - Edition 01.2015

Lamp for selector lever scale illumination - L101­Fitting location: The lamp for selector lever scale illumination -

L101- -1- is integrated in the bottom side of the cover frame -2-.

Selector lever - E313- with Tiptronic switch - F189- , selector lever
sensor control unit - J587- and selector lever switch locked in P ­F319-

Fitting location: Selector lever - E313- is firmly integrated in the
gearshift mechanism.

Tiptronic switch - F189- , Selector lever sensor control unit - J587­and Selector lever switch blocked in P - F319- are firmly integra‐
ted into the PCB -arrow- of the shift mechanism (up to 05.2009).

A new shift mechanism is fitted as of 06.2009, then the cover for
the bottom shift mechanism can no longer be removed in this way.

These components cannot be replaced separately.
The removal and installation procedure is only possible together

with the gearshift mechanism

⇒ “2.8 Removing and installing shift mechanism with selector lev‐
er control cable”, page 118 .

6. Electrical components 25

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Gearbox 0AM-DSG - Edition 01.2015

Brake light switch - F- and brake pedal switch - F47­Fitting location: The brake light switch - F- and brake pedal switch

- F47- -3- is located on the master brake cylinder -4-.

Kick-down switch - F8­An initialised value of the accelerator pedal position sender -

G79- / accelerator pedal position sender 2 - G185- (integrated in
the accelerator pedal module) is stored as a kick-down signal in
the engine control unit.

Fitting location: The accelerator pedal position sender - G79- /
accelerator pedal position sender 2 - G185- -arrow- are located
on the foot controls.

6.1.2 Electric/electronic components and fitting locations of the automatic gear‐
box DSG - 0AM (Fabia II and Roomster)

26 Rep. gr.00 - Technical data

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Gearbox 0AM-DSG - Edition 01.2015

1 - Diagnostic connection

❑ Fitting location: Dash

panel in the area of the
driver's footwell

2 - Selector lever position indi‐
cator - Y6-

❑ Fitting location: Integra‐

ted in the dash panel in‐
sert

❑ a switched off gear dis‐

play points to an emer‐
gency operation with
deactivated gearbox
control unit

❑ a fully lit gear display

points to an emergency
operation with activated
gearbox control unit

❑ can only be replaced to‐

gether with the dash
panel insert ⇒ Electrical
System; Rep. gr. 90

3 - Cover for shift mechanism
with lamp for selector lever
scale illumination - L101-

❑ the lamp for selector lev‐

er scale illumination ­L101- is integrated in
the cover for gearshift
mechanism -arrow-

❑ is checked by self-diag‐

nosis

❑ Removing and installing

⇒ “2.5 Removing and In‐
stalling the cover for the
shift mechanism”,
page 109

❑ as of 11.2012 (CW 45), the selector lever handle was changed

⇒ “2.1 Summary of components - Gearshift mechanism”, page 97

4 - Gearbox input r.p.m. sender - G182-

❑ Fitting location ⇒ page 28
❑ is checked by self-diagnosis
❑ is a component and can only be removed and installed with the° mechatronics for double clutch gearbox

- J743- ⇒ “1 Mechatronics for double clutch gearbox J743 ”, page 77

5 - Mechatronics for double clutch gearbox - J743-

❑ Fitting location ⇒ page 28
❑ is checked by self-diagnosis
❑ Removing and installing ⇒ “1 Mechatronics for double clutch gearbox J743 ”, page 77

6 - Selector lever lock solenoid - N110-

❑ Fitting location: Is integrated firmly in the gearshift mechanism and cannot be replaced separately
❑ is checked by self-diagnosis
❑ Removal and installation is only possible together with the gearshift mechanism

⇒ “2.8 Removing and installing shift mechanism with selector lever control cable”, page 118

7 - Selector lever - E313- with Tiptronic switch - F189- , selector lever sensor control unit - J587- and selector
lever switch locked in P - F319-

❑ is checked by self-diagnosis

6. Electrical components 27

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Gearbox 0AM-DSG - Edition 01.2015

❑ Tiptronic switch - F189- , selector lever sensor control unit - J587- and selector lever switch locked in P

- F319- are integrated into the shift mechanism.

❑ these components cannot be replaced separately; the removal and installation procedure is only possible

together with the gearshift mechanism

⇒ “2.8 Removing and installing shift mechanism with selector lever control cable”, page 118

8 - Brake light switch - F- and brake pedal switch - F47-

❑ Fitting location ⇒ page 28
❑ is checked by self-diagnosis
❑ removing and installing ⇒ Chassis; Rep. gr. 47

9 - Kick-down switch - F8-

❑ Fitting location ⇒ page 29
❑ Signal transfer from engine control unit to gearbox control unit via CAN databus
❑ is checked by self-diagnosis
❑ Removing and Installing ⇒ Engine; Rep. gr. 20

Mechatronics for double clutch gearbox - J743­Fitting location: The mechatronics for double clutch gearboxes -

J743- is screwed onto the front gearbox housing.
The control unit is firmly integrated in the mechatronics for double

clutch gearbox - J743- .
The senders and the actuators are located in the mechatronics

for double clutch gearbox - J743- . Further information can be
found in ⇒ Self-study programme No. 75 ; Automatic gearbox
DSG - 0AM .

Removing and installing the mechatronics for double clutch gear‐
box - J743-

⇒ “1 Mechatronics for double clutch gearbox J743 ”, page 77 .

Gearbox input r.p.m. sender - G182­Fitting location: The gearbox input speed sender - G182- is clip‐

ped onto the front of the gearbox housing. Release the sender for
removal and pull out in -direction of arrow-.

The gearbox input r.p.m. sender - G182- can only be replaced
together with the mechatronics for double clutch gearbox - J743-

⇒ “1 Mechatronics for double clutch gearbox J743 ”, page 77 .

Brake light switch - F- and brake pedal switch - F47­Fitting location: The brake light switch - F- and brake pedal switch

- F47- -3- is located on the master brake cylinder.

28 Rep. gr.00 - Technical data

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Gearbox 0AM-DSG - Edition 01.2015

Kick-down switch - F8­An initialised value of the accelerator pedal position sender -

G79- / accelerator pedal position sender 2 - G185- (integrated in
the accelerator pedal module) is stored as a kick-down signal in
the engine control unit.

Fitting location: Accelerator pedal position sender - G79- / accel‐
erator pedal position sender 2 - G185- -arrow- are located on the
foot controls.

6.1.3 Electric/electronic components and fitting locations of the automatic gear‐
box DSG - 0AM (Rapid)

1 - Diagnostic connection

❑ Fitting location: under

the cover in the driver's
footwell

2 - Selector lever position indi‐
cator - Y6-

❑ Fitting location: Integra‐

ted in the dash panel in‐
sert

❑ a switched off gear dis‐

play points to an emer‐
gency operation with
deactivated gearbox
control unit

❑ a fully lit gear display

points to an emergency
operation with activated
gearbox control unit

❑ can only be replaced to‐

gether with the dash
panel insert ⇒ Electrical
System; Rep. gr. 90

3 - Cover for shift mechanism
with lamp for selector lever
scale illumination - L101-

❑ the lamp for selector lev‐

er scale illumination ­L101- is integrated in
the cover for gearshift
mechanism

❑ is checked by self-diag‐

nosis

❑ Removing and installing

⇒ “2.5 Removing and In‐
stalling the cover for the
shift mechanism”,
page 109

6. Electrical components 29

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4 - Gearbox input r.p.m. sender - G182-

❑ Fitting location ⇒ page 31
❑ is checked by self-diagnosis
❑ is a component and can only be removed and installed with the° mechatronics for double clutch gearbox

- J743- ⇒ “1 Mechatronics for double clutch gearbox J743 ”, page 77

5 - Mechatronics for double clutch gearbox - J743-

❑ Fitting location ⇒ page 30
❑ is checked by self-diagnosis
❑ Removing and installing ⇒ “1 Mechatronics for double clutch gearbox J743 ”, page 77

6 - Brake light switch - F- and brake pedal switch - F47-

❑ Fitting location ⇒ page 31
❑ Signal transfer from engine control unit to gearbox control unit via CAN databus
❑ is checked by self-diagnosis
❑ removing and installing ⇒ Chassis; Rep. gr. 46

7 - Kick-down switch - F8-

❑ Fitting location ⇒ page 31
❑ Signal transfer from engine control unit to gearbox control unit via CAN databus
❑ is checked by self-diagnosis

❑ Removing and Installing ⇒ Engine; Rep. gr. 20
8 - Shift mechanism
Selector lever - E313- with Tiptronic switch - F189- , selector lever sensor control unit - J587- , selector lever

switch locked in P - F319- and selector lever lock solenoid - N110-

❑ is checked by self-diagnosis

❑ these components cannot be replaced separately, the removal and installation procedure is only possible

together with the gearshift mechanism

⇒ “2.8 Removing and installing shift mechanism with selector lever control cable”, page 118

Mechatronics for double clutch gearbox - J743­Fitting location: The mechatronics for double clutch gearboxes -

J743- is screwed onto the front gearbox housing.
The control unit is firmly integrated in the mechatronics for double

clutch gearbox - J743- .
The senders and the actuators are located in the mechatronics

for double clutch gearbox - J743- . Further information on the
same gearbox type 0AM can be found in ⇒ Self-study programme
No. 75 und Nr. 94 ; Automatic gearbox DSG - 0AM .

Removing and installing the mechatronics for double clutch gear‐
box - J743-

⇒ “1 Mechatronics for double clutch gearbox J743 ”, page 77 .

30 Rep. gr.00 - Technical data

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Gearbox input r.p.m. sender - G182­Fitting location: The gearbox input speed sender - G182- is clip‐

ped onto the front of the gearbox housing. Release the sender for
removal and pull out in -direction of arrow-.

The gearbox input r.p.m. sender - G182- can only be replaced
together with the mechatronics for double clutch gearbox - J743-

⇒ “1 Mechatronics for double clutch gearbox J743 ”, page 77 .

Selector lever - E313- with Tiptronic switch - F189- , selector lever
sensor control unit - J587- , selector lever switch locked in P ­F319- and selector lever lock solenoid - N110-

Fitting location: Is integrated firmly in the gearshift mechanism
and cannot be replaced separately.

Removal and installation is only possible together with the gear‐
shift mechanism

⇒ “2.8 Removing and installing shift mechanism with selector lev‐
er control cable”, page 118

Brake light switch - F- and brake pedal switch - F47­Fitting location: The brake light switch - F- and brake pedal switch

- F47- -3- is located on the master brake cylinder -4-.

Gearbox 0AM-DSG - Edition 01.2015

Kick-down switch - F8­An initialised value of the accelerator pedal position sender -

G79- / accelerator pedal position sender 2 - G185- (integrated in
the accelerator pedal module) is stored as a kick-down signal in
the engine control unit.

Fitting location: The accelerator pedal position sender - G79- /
accelerator pedal position sender 2 - G185- -arrow- are located
on the foot controls.

6. Electrical components 31

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30 – Clutch

1 Clutch operation

⇒ “1.1 Assembly overview - clutch release mechanism”,
page 32

⇒ “1.2 Removing and installing clutch release mechanism”, page
34

⇒ “1.3 Adjust clutch release mechanism”, page 41

1.1 Assembly overview - clutch release

mechanism

⇒ “1.1.1 Summary of components - Clutch release mechanism,
version up to 05.2011”, page 32

⇒ “1.1.2 Summary of components - Clutch release mechanism,
version as of 06.2011”, page 33

1.1.1 Summary of components - Clutch release mechanism, version up to

05.2011

1 - Small engaging lever for K2
clutch

❑ is removed and installed

together with the top
and bottom part of the
guide bushing

❑ replace when replacing

the double clutch

2 - Adjusting washer for K2
clutch

❑ replace when replacing

the double clutch

❑ Determine thickness

⇒ “1.3.1 Adjust clutch
release mechanism,
gearbox up to 05.2011”,
page 41

3 - Small engaging bearing for
K2 clutch

❑ replace when replacing

the double clutch

4 - Large engaging lever for K1
clutch

❑ together with large en‐

gaging bearing

❑ replace when replacing

the double clutch

5 - Adjusting washer for K1
clutch

❑ replace when replacing

the double clutch

❑ Determine thickness

⇒ “1.3.1 Adjust clutch
release mechanism,

32 Rep. gr.30 - Clutch

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Gearbox 0AM-DSG - Edition 01.2015

gearbox up to 05.2011”,
page 41

6 - Screw

❑ Replace after disassembly
❑ 8 Nm + 90°

7 - Clamp

❑ not present on some older gearboxes
❑ replace when replacing the double clutch

8 - Support for the engaging lever

❑ replace when replacing the double clutch

1.1.2 Summary of components - Clutch release mechanism, version as of

06.2011

1 - Adjusting washer for K1
clutch

❑ Determine thickness

⇒ “1.3.2 Adjusting the
clutch release mecha‐
nism, gearbox as of

06.2011”, page 51

2 - Large engaging lever for K1
clutch

❑ together with large en‐

gaging bearing

❑ replace when replacing

the double clutch

3 - Hinge bearing

❑ for large engaging lever

Pos. 2 2

❑ is not replaced

4 - Small engaging bearing for
K2 clutch

❑ replace when replacing

the double clutch

5 - Adjusting washer for K2
clutch

❑ Determine thickness

⇒ “1.3.2 Adjusting the
clutch release mecha‐
nism, gearbox as of

06.2011”, page 51

6 - Guide bushing-top part

❑ for small engaging lever

Pos. 7

❑ is removed and installed

together with the guide
bushing-bottom part
Pos. 7

7 - Small engaging lever for K2 clutch

❑ is removed and installed together with the top and bottom part of the guide bushing
❑ replace when replacing the double clutch

1. Clutch operation 33

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Gearbox 0AM-DSG - Edition 01.2015

8 - Ball pin

❑ for small engaging lever Pos. 7

❑ replace when replacing the double clutch
9 - Screw

❑ Replace after disassembly

❑ 8 Nm + 90°
10 - Guide bushing-bottom part

❑ for small engaging lever Pos. 7

❑ is removed and installed together with the guide bushing-top part Pos. 6

1.2 Removing and installing clutch release

mechanism

⇒ “1.2.1 Removing and installing clutch release mechanism, ver‐
sion up to 05.2011”, page 34

⇒ “1.2.2 Removing and installing clutch release mechanism, ver‐
sion as of 06.2011”, page 37

1.2.1 Removing and installing clutch release

mechanism, version up to 05.2011

Caution

If the double clutch has to be replaced, the following parts must
always be replaced too:

♦ The two engaging levers with the gear shift bearings
♦ Bearing of the engaging lever
♦ Shims for gear shift bearings

After replacing the double clutch and the corresponding parts,
the position of the gear shift bearings for clutches K1 and K2
will always require re-adjusting

⇒ “1.3.1 Adjust clutch release mechanism, gearbox up to

05.2011”, page 41

Note

♦

If all the listed parts are only removed and installed, no re­adjustment is necessary.

♦

The circlip must be replaced under all circumstances.

• Double clutch gearbox removed

⇒ “2.2 Remove double clutch”, page 66

• The mechatronics for double clutch gearbox -J743- is installed

on the gearbox

34 Rep. gr.30 - Clutch

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Removing
– Remove the small engaging bearing with the adjusting wash‐

er.

– Remove the large engaging lever.

Gearbox 0AM-DSG - Edition 01.2015

– Remove screws and remove the small engaging lever with

clamp.

Note

Only some older gearboxes have no clamp.

– Remove the support for the engaging lever.
Installing
The large adjusting washer for the clutch K1 is installed on the

large bearing, the small adjusting washer for the clutch K2 is in‐
stalled under the small bearing.

Caution

Do not oil or grease!

1. Clutch operation 35

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Gearbox 0AM-DSG - Edition 01.2015

– Insert the plastic support of the engaging levers and check for

correct fit.

Note

Only some older gearboxes have no clamp. New gearboxes al‐
ways have a clamp.

– Use two screws to install the small engaging lever with clamp.

• The support of the engaging levers and the complete mecha‐

nism for the engaging bearings must be dry and free of oil or
grease.

• If necessary, clean these component parts with a clean cloth.

– Insert the large engaging lever.
This larger engaging lever is for clutch K1.
– Check the correct fit of both engaging levers.

– Insert the small engaging bearing -A- for K2 with the measured

adjusting washer -B-.

Determine the thickness of the adjusting washer

⇒ “1.3 Adjust clutch release mechanism”, page 41

The adjusting washer -B- belongs under the small engaging bear‐
ing -A-. Therefore, insert the adjusting washer first.

36 Rep. gr.30 - Clutch

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• The small engaging bearing fits in only one position due to the
4 grooves.

– While turning in -direction of arrow-, check if the small engag‐

ing bearing is correctly installed and the grooves are correctly
positioned.

Gearbox 0AM-DSG - Edition 01.2015

– Fix adjusting washer for K1 -A- with 3 drops of adhesive - AMV

195 KD1 01- -arrows- on the bearing.

This prevents that the washer slips out of its position when the
clutch is inserted.

Specified torques
♦ Small engaging lever with clamp on gearbox

⇒ “1.1.1 Summary of components - Clutch release mecha‐
nism, version up to 05.2011”, page 32

1.2.2 Removing and installing clutch release

mechanism, version as of 06.2011

Caution

When replacing the double clutch, the following parts must al‐
ways be replaced too:

♦ the two engaging levers with engaging bearings
♦ Ball pin of the engaging lever for clutch K2
♦ Shims for engaging bearing

After replacing the double clutch and the corresponding parts,
the position of the engaging bearings for clutches K1 and K2
will always require re-adjusting

⇒ “1.3.2 Adjusting the clutch release mechanism, gearbox as
of 06.2011”, page 51 .

1. Clutch operation 37

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Gearbox 0AM-DSG - Edition 01.2015

Note

♦

If all the mentioned parts are only removed and reinstalled,
there is nothing to adjust.

♦

The circlip must be replaced under all circumstances.

• Double clutch gearbox removed

⇒ “2.2 Remove double clutch”, page 66

• Mechatronics for double clutch gearbox -J743- installed

Removing
– Remove large engaging lever together with the shims and

bearing.

Note

Guide bushing top part cannot be removed or installed individu‐
ally. It is always removed and installed together with the guide
bushing bottom part and small engaging bearing.

– Remove screws and remove the small engaging lever.

If no parts are replaced, the ball pin -2- remains installed.

Note

The hinge bearing -1- cannot be removed.

Installing
The large adjusting washer for the clutch K1 is inserted with the

semispherical side downwards on the large bearing, the small
adjusting washer for the clutch K2 is inserted under the small
bearing.

Caution

Do not oil or grease!

38 Rep. gr.30 - Clutch

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– Insert ball pin -2-.
Installation instructions for the new engaging lever K2

The new engaging lever K2 is delivered with guide bushing upper
and lower part in the transport position. It must be brought to fitting
position before installation.

Gearbox 0AM-DSG - Edition 01.2015

– Only guide bushing upper part by hand.
– Turn the guide bushing bottom part with your other hand in the

-direction of arrow- at the same time so that the sleeve can be
moved freely.

Since a large amount of force is needed to turn the guide bushing
bottom part, hold the two parts of the engaging lever firm.

1. Clutch operation 39

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Gearbox 0AM-DSG - Edition 01.2015

In the installation position, the openings of the guide bushing bot‐
tom part lie vertically to the engaging lever and the sleeve can be
moved freely at the same time.

– Insert the small engaging lever with the top and bottom part of

the guide bushing and tighten the screws.

– Insert the second, larger engaging lever with the measured

adjusting washers for clutch K1 and K2.

The large adjusting washer for the clutch K1 is inserted with the
semispherical side downwards on the large bearing, the small
adjusting washer for the clutch K2 is inserted under the small
bearing.

The small engaging bearing and the adjusting washer fit in only
one position due to the 8 grooves.

– Insert the small engaging bearing.
– While turning the bearing, check if it is correctly installed and

the grooves are correctly positioned.

– Check the correct fit of both engaging levers.
Specified torques
♦ Small engaging lever on gearbox

⇒ “1.1.2 Summary of components - Clutch release mecha‐
nism, version as of 06.2011”, page 33

40 Rep. gr.30 - Clutch

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1.3 Adjust clutch release mechanism

⇒ “1.3.1 Adjust clutch release mechanism, gearbox up to

05.2011”, page 41
⇒ “1.3.2 Adjusting the clutch release mechanism, gearbox as of

06.2011”, page 51

1.3.1 Adjust clutch release mechanism, gear‐
box up to 05.2011

Special tools and workshop equipment required
♦ Gauge block - T10374­♦ Straightedge - T40100­♦ Adhesive - AMV 195 KD1 01­♦ Digital depth gauge

Caution

When replacing the double clutch, the following parts must al‐
ways be replaced too:

Gearbox 0AM-DSG - Edition 01.2015

♦ the two engaging levers with engaging bearings
♦ Bearing of the engaging lever
♦ Shims for engaging bearing

After replacing the double clutch and the corresponding parts,
the position of the engaging bearings for clutches K1 and K2
will always require re-adjusting.

Note

♦

If all the mentioned parts are only removed and reinstalled,
there is nothing to adjust.

♦

The circlip must be replaced under all circumstances.

Conditions

• The mechatronics is installed.

• Double clutch gearbox removed

⇒ “2.2 Remove double clutch”, page 66

• Only use proper tools.

• The flange of the clutch housing must be free of irregularities,

as the only way to ensure good contact with the straightedge.
Short description
The position of the engaging bearing is comparable with the

clutch play of a mechanical manual gearbox. In the automatic
gearbox DSG - 0AM, there are tolerances in the engaging system
of the gearbox and in the gearbox itself. Tolerances also exist
inside the double clutch. These tolerances must be considered
separately when adjusting.

In the following procedure, you will first see how to determine all
the necessary dimensions on the gearbox side in order to identify
the suitable adjusting washer. This has an impact on the clutch
tolerances determined earlier by the manufacturer. The toleran‐

1. Clutch operation 41

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Gearbox 0AM-DSG - Edition 01.2015

ces on the gearbox side and the tolerances in the clutch deter‐
mine the thickness of the adjusting washer.

• The order of work steps must be observed!

Caution

Risk of damage to the clutch as well as to other components.
Bearing of the engaging lever and the entire engaging bearing

mechatronics must be dry and free of oil and grease.

Preparation
– Install the parts of the clutch up to the large engaging lever

⇒ “1.2.1 Removing and installing clutch release mechanism,
version up to 05.2011”, page 34 .

• Do not install the small engaging bearing and do not insert an
adjusting washer.

– Install the circlip of the outer drive shaft -arrow-.

Determine dimension -B-.

42 Rep. gr.30 - Clutch

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– Place the straightedge - T40100- upright on the flange of the

clutch housing.

Caution

The straightedge - T40100- must remain in this position during
the following measurements.

Do not turn or remove it.

– Place the digital depth gauge -A- on the outer drive shaft -B-.
– Perform null balance of the depth gauge .

Gearbox 0AM-DSG - Edition 01.2015

– Measure the distance to the circlip.
– Note the result and name it B1.

Example: B1 = 2.91 mm

– Measure the dimension B once more at the opposite point.
– Note the result and name it B2.

• Do not measure on the joint of the ring. The ring could be
pressed off from the joint and thus the measuring result will be
inaccurate.

– Remove circlip again.

• This ring must not be re-used!

– Determine the mean value from both measurement results.
Example:

Dimension B = B1 + B2 2 = 2.91+3.02 = 2.96

1. Clutch operation 43

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Gearbox 0AM-DSG - Edition 01.2015

Determine dimension -A1- of the large engaging bearing for clutch
K1.

• Do not insert an adjusting washer!

– Position the gauge block - T10374- on the large engaging

bearing.
The flat side faces upwards.
– Press on the gauge block - T10374- , and simultaneously ro‐

tate to ensure correct seating.

• The gear shift bearing rotates with the gauge block - T10374- .

– Attach the digital depth gauge upwards on the straightedge

and place the rod of the depth gauge on the outer driveshaft.

• The straightedge - T40100- is already positioned upright on

the flange of the clutch housing.

Caution

The straightedge - T40100- must remain in this position during
the following measurements.

Do not turn or remove it.

– Perform null balance of the digital depth gauge .

– Position the rod of the digital depth gauge on the gauge block

- T10374- , as shown in the figure, and measure the distance

from the shaft end.

44 Rep. gr.30 - Clutch

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– Position the digital depth gauge twice at opposite-facing points

for a precise measurement.

In this way, an even more precise value is determined as the in‐
accuracy resulting from the wobbling on the engaging bearing is
thus minimised.

– Calculate the mean value of both measurements.
– Note this value and name it A1.
Example:

Dimension A1 = 2.61+2.812 = 2.71
Result: Dimension A1 = 2.71 mm
Determining the installation depth of the gear shift bearing for

clutch K1
On the basis of measured dimension A1 and dimension B, the

actual value for the installation depth of the gear shift bearing for
clutch K1 is determined by the following calculation.

Dimension A1

- Dimension B

+ Height of the gauge block - T10374- (fixed value

51.81 mm)

= Actual value for the installation depth of the gear shift bear‐

ing K1

Gearbox 0AM-DSG - Edition 01.2015

Example calculation:
♦ 2.71 mm – 2.96 mm + 51.81 mm = 51.56 mm
♦ Value for the installation depth of gear shift bearing for clutch

K1 = 51.56 mm
Determining the clutch play of K1
The clutch play of clutch K1 is now determined as follows on the

basis of the actual value and the specified value for the installation
depth of the gear shift bearing.

Actual value for the installation depth of the gear shift bear‐
ing

- Specified value for the installation depth of the gear shift
bearing (50.08 mm, fixed value)

= Clutch play of clutch K1

Example calculation:
♦ 51.56 mm – 50.08 mm = 1.48 mm
♦ Clutch play of clutch K1 = 1.48 mm
Determining the clutch tolerance of clutch K1

1. Clutch operation 45

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– Please read off the value of the clutch tolerance from the new

clutch.

♦ The clutch tolerance value you have read off for clutch K1 is

0.0 mm
Determining the thickness of the adjusting washer SK1
The thickness of adjusting washer SK1 is now determined as fol‐

lows on the basis of the determined clutch play and clutch toler‐
ance for clutch K1.

Clutch play of clutch K1

-/+ Clutch tolerance of clutch K1
= Determined thickness of adjusting washer SK1

Example calculation:
♦ 1.48 mm + 0.0 mm = 1.48 mm
♦ Determined thickness of adjusting washer SK1 = 1.48 mm
– Select the correct washer from the table.

Determined thickness of the

washer

from to
0,31 0,90 0,8
0,91 1,10 1,0
1,11 1,30 1,2
1,31 1,50 1,4
1,51 1,70 1,6
1,71 1,90 1,8
1,91 2,10 2,0
2,11 2,30 2,2
2,31 2,50 2,4
2,51 2,70 2,6
2,71 3,30 2,8

Example:
♦ Determined thickness of adjusting washer SK1 = 1.48 mm
♦ Selected thickness of the adjusting washer = 1.4 mm

– Measure all the adjusting washers and prepare the corre‐

sponding adjusting washer for installation.

Washer to be installed in mm

Caution

Risk of damage to gearbox!

♦ Mark adjusting washer SK1 and prepare it as follows for

installation.

♦ Only this adjusting washer SK1 may be used for adjust‐

ment

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Determine dimension -A2- of the small engaging bearing for
clutch K2.

– Only insert the small bearing.

Gearbox 0AM-DSG - Edition 01.2015

The small engaging bearing fits in only one position due to the 4
grooves.

– While turning -arrows-, check if the small engaging bearing is

correctly installed and the grooves are correctly positioned.

• Do not insert an adjusting washer!

1. Clutch operation 47

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– Position the gauge block - T10374- with the large opening up‐

wards on the small bearing.

– Lay the straightedge - T40100- at a right angle over the shaft

end onto the gearbox flange.

– Attach the digital depth gauge upwards on the straightedge -

T40100- and place the rod of the depth gauge onto the outer
driveshaft.

– Perform null balance of the digital depth gauge .

Caution

The straightedge - T40100- must remain in this position during
the following measurements.

Do not turn or remove it.

– Place the rod of the depth gauge on the gauge block -

T10374- , as shown in the figure.

– Measure the distance of A2 from the shaft end to the gauge

block - T10374- .

48 Rep. gr.30 - Clutch

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Position the digital depth gauge twice at opposite-facing points
for a precise measurement.

In this way, an even more precise value is determined as the in‐
accuracy resulting from the wobbling on the engaging bearing is
thus minimised.

– Calculate the mean value of both measurements to the gauge

block - T10374- .
– Note this value and name it A2.
Example calculation:
♦ Dimension A2 = 2.50 + 2.542 = 2.52
♦ Result: A2 = 2.52 mm
Determining the installation depth of the gear shift bearing for

clutch K2
On the basis of measured dimension A2 and dimension B, the

actual value for the installation depth of the gear shift bearing for
clutch K2 is determined by the following calculation.

Dimension A2

- Dimension B

+ Inside height of the gauge block - T10374- (fixed value

36.20 mm)

= Actual value for the installation depth of the gear shift bear‐

ing K2

Gearbox 0AM-DSG - Edition 01.2015

Example calculation:
♦ 2.52 mm – 2.96 mm + 36.20 mm = 35.76 mm
♦ Result: Actual value for the installation depth of the gear shift

bearing K2 - 35.76 mm
Determining the clutch play of K2
The clutch play of clutch K2 is now determined as follows on the

basis of the actual value and the specified value for the installation
depth of the gear shift bearing.

Actual value for the installation depth of the gear shift bear‐
ing

- Specified value for the installation depth of the gear shift
bearing (34.35 mm, fixed value)

= Clutch play of clutch K2

Example calculation:
♦ 35.76 mm – 34.35 mm = 1.41 mm
♦ Result: Clutch play of clutch K2 = 1.41 mm
Determining the clutch tolerance of clutch K2

1. Clutch operation 49

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– Please read off the value of the clutch tolerance from the new

clutch.

♦ The clutch tolerance value you have read off for clutch K2 is

0.4 mm
Determining the thickness of the adjusting washer SK2
The thickness of adjusting washer SK2 is now determined as fol‐

lows on the basis of the determined clutch play and clutch toler‐
ance for clutch K2.

Clutch play of clutch K2

-/+ Clutch tolerance of clutch K2
= Determined thickness of adjusting washer SK2

Example calculation:
♦ 1.41 mm minus +0.4 mm = 1.81 mm
♦ Determined thickness of adjusting washer SK2 = 1.81 mm
– Select the correct washer from the table.

Determined thickness of the

washer

from to
0,31 0,90 0,8
0,91 1,10 1,0
1,11 1,30 1,2
1,31 1,50 1,4
1,51 1,70 1,6
1,71 1,90 1,8
1,91 2,10 2,0
2,11 2,30 2,2
2,31 2,50 2,4
2,51 2,70 2,6
2,71 3,30 2,8

Example:
♦ Determined thickness of adjusting washer SK2 = 1.81 mm
♦ Selected thickness of the adjusting washer = 1.8 mm

Shim to be installed in millime‐

tres

50 Rep. gr.30 - Clutch

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...

– Measure all the adjusting washers and prepare the corre‐

sponding adjusting washer for installation.

Caution

Risk of damage to gearbox!

♦ Mark adjusting washer SK2 and prepare it as follows for

installation.

♦ Only this adjusting washer SK2 may be used for adjust‐

ment.

The adjusting washer for K2 is then also determined. Please in‐
stall this adjusting washer when installing the clutch at a later
stage. This washer belongs under the small engaging bearing.

The clutch can be installed

⇒ “2.3 Install double clutch”, page 69 .

1.3.2 Adjusting the clutch release mecha‐
nism, gearbox as of 06.2011

Special tools and workshop equipment required
♦ Gauge block - T10466­♦ Straightedge - T40100­♦ Digital depth gauge

Gearbox 0AM-DSG - Edition 01.2015

Caution

When replacing the double clutch, the following parts must al‐
ways be replaced too:

♦ the two engaging levers with engaging bearings
♦ Ball pin of the engaging lever for clutch K2
♦ Shims for engaging bearing

After replacing the double clutch and the corresponding parts,
the position of the engaging bearings for clutches K1 and K2
will always require re-adjusting.

Note

♦

If all the mentioned parts are only removed and reinstalled,
there is nothing to adjust.

♦

The circlip must be replaced under all circumstances.

Short description
The position of the engaging bearing is comparable with the

clutch play of a mechanical manual gearbox. In the automatic
gearbox DSG - 0AM, there are tolerances in the engaging system
of the gearbox and in the gearbox itself. Tolerances also exist
inside the double clutch. These tolerances must be considered
separately when adjusting.

In the following procedure, you will first see how to determine all
the necessary dimensions on the gearbox side in order to identify
the suitable adjusting washer. The tolerances on the gearbox side

1. Clutch operation 51

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and the tolerances in the clutch determine the thickness of the
adjusting washer.

Conditions

• Double clutch gearbox removed

⇒ “2.2 Remove double clutch”, page 66

• The mechatronics is installed.

• Only use proper tools.

• The flange of the clutch housing must be free of irregularities,
as the only way to ensure good contact with the straightedge.

• The order of work steps must be observed!

Caution

Risk of damage to the clutch as well as to other components.
Bearing of the engaging lever and the entire engaging bearing

mechatronics must be dry and free of oil and grease.

Removing and installing the ball pin
– Remove the ball pin with the pliers.

– Install a new ball pin.

Note

Press in the ball pin by hand, if necessary slightly drive in with a
plastic hammer (in order not to damage the ball pin).

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– Install the old circlip of the outer drive shaft -arrow-.

Determine dimension -B-.

Gearbox 0AM-DSG - Edition 01.2015

– Place the straightedge - T40100- upright on the flange of the

clutch housing.

Caution

The straightedge - T40100- must remain in this position during
the following measurements.

Do not turn or remove it.

– Place the digital depth gauge -A- on the outer drive shaft -B-.
– Perform null balance of the digital depth gauge .

1. Clutch operation 53

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– Measure the distance to the circlip.
– Note the result and name it B1.

Example: Dimension B1 = 2.62 mm

– Measure the dimension B once more at the opposite point.
– Note the result and name it B2.

• Do not measure on the joint of the ring. The ring could be
pressed off from the joint and thus the measuring result will be
inaccurate.

♦ Example: Dimension B2 = 2.58 mm

– Determine the mean value from both measurement results.
Example:
♦ Dimension B = B1+B2 2 = 2.62+2.582 = 2.60

This dimension B is required for the following calculations.

– Remove the circlip -arrow- again.

• The circlip may not be reused.

Determine dimension -A1- of the large engaging bearing for clutch
K1.

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– Insert the large engaging lever.

• Do not insert an adjusting washer!

– Position the gauge block - T10466- on the large engaging

bearing.
The flat side faces upwards.
– Press on the gauge block - T10466- , and simultaneously ro‐

tate to ensure correct seating.

• The gear shift bearing rotates with the gauge block - T10466- .

Gearbox 0AM-DSG - Edition 01.2015

– Attach the digital depth gauge upwards on the straightedge

and place the rod of the depth gauge on the outer driveshaft.

• The straightedge - T40100- is already positioned upright on

the flange of the clutch housing.

Caution

The straightedge - T40100- must remain in this position during
the following measurements.

Do not turn or remove it.

– Perform null balance of the digital depth gauge .

– Position the rod of the digital depth gauge on the gauge block

- T10466- , as shown in the figure, and measure the distance

from the shaft end.

1. Clutch operation 55

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– Perform a second measurement at the opposite point of the

gauge block - T10466- in the same way.

In this way, an even more precise value is determined as the in‐
accuracy resulting from the wobbling on the engaging bearing is
thus minimised.

– Calculate the mean value A1 of both measurements to the

gauge block - T10466- .
– Note this value and name it A1.
Example
♦ Dimension A1 = 4.93+4.912 = 4.92
♦ Result: A1 = 4.92 mm
Determining the height tolerance of the gear shift bearing for

clutch K1
On the basis of measured dimension A1 and dimension B, the

actual value for the height tolerance of the gear shift bearing for
clutch K1 is determined by the following calculation.

Dimension A1

- Dimension B

= Height tolerance of the gear shift bearing for clutch K1

Example
♦ 4.92 mm – 2.60 mm = 2.32 mm
♦ Height tolerance of gear shift bearing for clutch K1 = 2.32 mm
Determining the clutch tolerance of clutch K1

56 Rep. gr.30 - Clutch

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– Please read off the value of the clutch Tolerance -arrow- from

the new clutch.

A value between minus 0.40 and plus 0.40 mm is marked on the
new clutch.

♦ The clutch tolerance value you have read off for clutch K1 is

0.0 mm
Determining the thickness of the adjusting washer SK1
The thickness of adjusting washer SK1 is now determined as fol‐

lows on the basis of the determined clutch tolerance for clutch K1.

Height tolerance of the gear shift bearing for clutch K1

-/+ Clutch tolerance of clutch K1
= Determined thickness of adjusting washer SK1

Example calculation:
♦ 2.32 mm + 0.0 mm = 2.32 mm
♦ Determined thickness of adjusting washer SK1 = 2.32 mm
– Select the correct washer from the table and put it aside until

you are ready to install it.

Gearbox 0AM-DSG - Edition 01.2015

Deter‐

mined
thickness
of the ad‐

justing

washer

mm

1,21...1,60 1,50 0AM 141 383
1,61...1,80 1,70 0AM 141 383 A
1,81...2,00 1,90 0AM 141 383 B
2,01...2,20 2,10 0AM 141 383 C
2,21...2,40 2,30 0AM 141 383 D
2,41...2,60 2,50 0AM 141 383 E
2,61...2,80 2,70 0AM 141 383 F
2,81...3,00 2,90 0AM 141 383 G
3,01...3,20 3,10 0AM 141 383 H
3,21...3,40 3,30 0AM 141 383 J
3,41...3,80 3,50 0AM 141 383 K

Example:
♦ Determined thickness of adjusting washer SK1 = 2.32 mm
♦ Selected thickness of the adjusting washer = 2.30 mm (part

number 0AM 141 383 D)

Available adjusting

washers thickness

in mm

Part number

Caution

Risk of damage to gearbox!

♦ Mark adjusting washer SK1 and prepare it as follows for

installation.

♦ Only this adjusting washer SK1 may be used for adjust‐

ment

1. Clutch operation 57

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– Remove the gauge block - T10466- and remove the large en‐

gaging lever.

Determine dimension -A2- of the small engaging bearing for
clutch K2.

Guide bushing top part cannot be removed or installed individu‐
ally. It is always removed and installed together with the guide
bushing bottom part and small engaging bearing.

The new engaging lever K2 is delivered with guide bushing upper
and lower part in the transport position. It must be brought to fitting
position before installation.

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– Only guide bushing upper part by hand.
– Turn the guide bushing bottom part with your other hand in the

-direction of arrow- at the same time so that the sleeve can be
moved freely.

Since a large amount of force is needed to turn the guide bushing
bottom part, hold the two parts of the engaging lever firm.

In the installation position, the openings of the guide bushing bot‐
tom part lie vertically to the engaging lever and the sleeve can be
moved freely at the same time.

Gearbox 0AM-DSG - Edition 01.2015

– Insert the small engaging lever with the top and bottom part of

the guide bushing and tighten the screws.

1. Clutch operation 59

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– Insert the small engaging bearing.

The small engaging bearing fits in only one position due to the 8
grooves.

– While turning, check if the small engaging bearing is correctly

installed and the grooves are correctly positioned.

• Do not insert an adjusting washer!

– Position the gauge block - T10466- on the small engaging

bearing.

• The flat side faces upwards.
– Press on the gauge block - T10466- , and simultaneously ro‐

tate to ensure correct seating.

• The gear shift bearing rotates with the gauge block - T10466- .

– Attach the digital depth gauge upwards on the straightedge

and place the rod of the depth gauge on the outer driveshaft.

• The straightedge - T40100- is already positioned upright on
the flange of the clutch housing.

Caution

The straightedge - T40100- must remain in this position during
the following measurements.

Do not turn or remove it.

– Perform null balance of the digital depth gauge .

60 Rep. gr.30 - Clutch

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– Position the rod of the digital depth gauge on the gauge block

- T10466- , as shown in the figure, and measure the distance
from the shaft end.

– Position the digital depth gauge twice at opposite-facing points

for a precise measurement.

In this way, an even more precise value is determined as the in‐
accuracy resulting from the wobbling on the engaging bearing is
thus minimised.

– Calculate the mean value of both measurements.
– Note this value and name it A2.
Example

Dimension A2 = 4.79 + 4.752 = 4.77
Result: A2 = 4.77 mm
Determining the height tolerance of the gear shift bearing for

clutch K2
On the basis of dimension A2 and dimension B, the tolerance of

the gear shift bearing for clutch K2 is determined by the following
calculation.

Dimension A2

- Dimension B

= Height tolerance of the gear shift bearing for clutch K2

Gearbox 0AM-DSG - Edition 01.2015

Example calculation:
♦ 4.77 mm – 2.60 mm = 2.17 mm
♦ Height tolerance of gear shift bearing for clutch K2 = 2.17 mm
Determining the clutch tolerance of clutch K2

1. Clutch operation 61

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– Please read off and note the value of the clutch tolerance from

the new clutch -arrow-.
Example: K2 “+ 0.4 mm” is given on the clutch.
Determining the thickness of the adjusting washer “SK2”
The thickness of adjusting washer “SK2” is now determined as

follows on the basis of the determined clutch play and clutch tol‐
erance for clutch “K2”.

Height tolerance of the gear shift bearing for clutch “K2”

-/+ Clutch tolerance of clutch “K2”
= Determined thickness of adjusting washer “SK2”

Example calculation:
♦ 2.17 mm + 0.4 mm = 2.57 mm
♦ Determined thickness of adjusting washer “SK2” = 2.57 mm
– Select the correct washer from the table.

Determined thickness of the

washer

from to
0,31 0,90 0,8
0,91 1,10 1,0
1,11 1,30 1,2
1,31 1,50 1,4
1,51 1,70 1,6
1,71 1,90 1,8
1,91 2,10 2,0
2,11 2,30 2,2
2,31 2,50 2,4
2,51 2,70 2,6
2,71 3,30 2,8

Example:
♦ Determined thickness of adjusting washer “SK2” = 2.57 mm
♦ Selected thickness of the adjusting washer = 2.60 mm

– From the delivered washers, determine the required adjusting

washer and put it aside until you are ready to install it.

Shim to be installed in millime‐

tres

Caution

Risk of damage to gearbox!

♦ Mark adjusting washer SK2 and prepare it as follows for

installation.

♦ Only this adjusting washer SK2 may be used for adjust‐

ment.

– Install clutch ⇒ “2.3 Install double clutch”, page 69 .

62 Rep. gr.30 - Clutch

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Gearbox 0AM-DSG - Edition 01.2015

2 Clutch

⇒ “2.1 Summary of components - double clutch”, page 63
⇒ “2.2 Remove double clutch”, page 66
⇒ “2.3 Install double clutch”, page 69
⇒ “2.4 Replacing the sealing ring for the outer drive shaft”,

page 74
⇒ “2.5 Replace gasket ring for inner drive shaft”, page 75

2.1 Summary of components - double clutch

⇒ “2.1.1 Summary of components - double clutch up to 05.2011”,
page 63

⇒ “2.1.2 Summary of components - double clutch as of 06.2011”,
page 65

2.1.1 Summary of components - double clutch up to 05.2011

1 - Circlip

❑ Replace after disas‐

sembly
2 - Hub
3 - Circlip

❑ Replace after disas‐

sembly
4 - Large engaging lever for K1

clutch

❑ with large engaging

bearing

❑ Removing and installing

⇒ “1.2.1 Removing and

installing clutch release

mechanism, version up

to 05.2011”, page 34

❑ replace when replacing

the double clutch gear‐

box
5 - Small engaging lever for K2

clutch

❑ replace when replacing

the double clutch gear‐

box

❑ Removing and installing

⇒ “1.2.1 Removing and

installing clutch release

mechanism, version up

to 05.2011”, page 34

6 - Screw

❑ Replace after disas‐

sembly

❑ 8 Nm + 90°

7 - Support

❑ for engaging lever
❑ replace when replacing the double clutch gearbox

2. Clutch 63

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8 - Clamp

❑ for small engaging lever
❑ not present on older versions
❑ replace when replacing the double clutch gearbox

9 - Sealing ring

❑ for inner drive shaft
❑ Renew ⇒ “2.5 Replace gasket ring for inner drive shaft”, page 75 .

10 - Sealing ring

❑ for outer drive shaft

❑ Renew ⇒ “2.4 Replacing the sealing ring for the outer drive shaft”, page 74 .
11 - Outer drive shaft
12 - Adjusting washer SK1

❑ Determine thickness ⇒ “1.3.1 Adjust clutch release mechanism, gearbox up to 05.2011”, page 41
13 - Adjusting washer SK2

❑ Determine thickness ⇒ “1.3.1 Adjust clutch release mechanism, gearbox up to 05.2011”, page 41
14 - Small engaging bearing for K2 clutch

❑ Removing and installing

⇒ “1.2.1 Removing and installing clutch release mechanism, version up to 05.2011”, page 34

❑ replace when replacing the double clutch gearbox
15 - Double clutch

❑ removing ⇒ “2.2 Remove double clutch”, page 66

❑ installing ⇒ “2.3 Install double clutch”, page 69

64 Rep. gr.30 - Clutch

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Gearbox 0AM-DSG - Edition 01.2015

2.1.2 Summary of components - double clutch as of 06.2011

1 - Hinge bearing

❑ for large engaging lever

for K1 clutch

❑ is not replaced

2 - Ball pin

❑ for small engaging lever

for K1 clutch

❑ Removing and installing

⇒ “1.2.2 Removing and
installing clutch release
mechanism, version as
of 06.2011”, page 37

❑ replace when replacing

the double clutch gear‐
box

3 - Adjusting washer SK1

❑ Determine thickness

⇒ “1.3.2 Adjusting the
clutch release mecha‐
nism, gearbox as of

06.2011”, page 51

4 - Adjusting washer SK2

❑ Determine thickness

⇒ “1.3.2 Adjusting the
clutch release mecha‐
nism, gearbox as of

06.2011”, page 51

5 - Small engaging bearing for
K2 clutch

❑ replace when replacing

the double clutch gear‐
box

6 - Double clutch

❑ removing

⇒ “2.2 Remove double clutch”, page 66

❑ installing ⇒ “2.3 Install double clutch”, page 69

7 - Circlip

❑ Replace after disassembly
8 - Hub
9 - Circlip

❑ Replace after disassembly
10 - Large engaging lever for K1 clutch

❑ with engaging bearing

❑ Removing and installing

⇒ “1.2.2 Removing and installing clutch release mechanism, version as of 06.2011”, page 37

❑ replace when replacing the double clutch gearbox
11 - Guide bushing-top part

❑ for small engaging lever for K2

❑ remove and install together with the small engaging lever Pos. 12 and guide bushing bottom part Pos.

14

2. Clutch 65

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Gearbox 0AM-DSG - Edition 01.2015

12 - Small engaging lever for K2 clutch

❑ is removed and installed together with the top and bottom part of the guide bushing Pos. 11 and 14
❑ Removing and installing

⇒ “1.2.2 Removing and installing clutch release mechanism, version as of 06.2011”, page 37

❑ replace when replacing the double clutch gearbox

13 - Screw

❑ Replace after disassembly
❑ 8 Nm + 90°

14 - Guide bushing-bottom part

❑ for small engaging lever for K2
❑ remove and install together with the small engaging lever Pos. 12 and guide bushing top part Pos. 11

15 - Sealing ring

❑ for inner drive shaft
❑ Renew ⇒ “2.5 Replace gasket ring for inner drive shaft”, page 75 .

16 - Sealing ring

❑ for outer drive shaft
❑ Renew ⇒ “2.4 Replacing the sealing ring for the outer drive shaft”, page 74 .

2.2 Remove double clutch

Special tools and workshop equipment required
♦ Assembly stand - MP9-101­♦ Hook - 3438­♦ Supporting bridge - T10323­♦ Thrust piece - T10368­♦ Extractor - T10373­♦ Thrust piece - T10376­♦ Gearbox mount - T30108­♦ Gearbox mount - T30109 (VW 353)-

66 Rep. gr.30 - Clutch

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...

Detach the clutch upwards when the gearbox is removed. The
mechatronics remains on the gearbox.

If a new clutch is installed, the positions of the engaging bearings
for clutches K1 and K2 must be determined and adjusted

⇒ “1.3 Adjust clutch release mechanism”, page 41 .

Then the clutch is pressed onto the drive shaft.
When installing a clutch, most mechanics press the clutch onto

the drive shaft up to the stop. This is not the optimum position of
the clutch!

After installation, the clutch is therefore pulled slightly upwards
against the circlip.

Caution

Risk of damage to the adjusting device of the clutch.

♦ The clutch is self-adjusting. Vibrations can have a nega‐

tive effect on the adjusting device. Therefore do not let the
clutch fall. Do not let the clutch fall into the gearbox when
installing it.

♦ A clutch that has been dropped on a hard surface, or which

is otherwise damaged, must no longer be installed.

♦ Similarly when the mechatronics is removed, the removal

of the drifts below the engaging levers can have a negative
effect on the adjusting device.

Gearbox 0AM-DSG - Edition 01.2015

• Gearbox removed

⇒ “3 Removing and installing the gearbox”, page 132

• Gearbox attached to assembly stand

⇒ “4 Transport the gearbox and secure to the assembly sup‐
port”, page 172

• The mechatronics for double clutch gearbox - J743- is installed

on the gearbox

– Detach both ventilation caps -arrows- and close in an oil-tight

manner with suitable screw plugs.

Caution

The ventilation cap on the mechatronics is damaged when re‐
moved and must be replaced!

The oil filling in the area with the hydraulic oil for mechatronics
can not be checked. Before assembly work, the ventilation of
the mechatronics must be sealed oil-tight.

The oil escaping from the area with hydraulic oil for mecha‐
tronics cannot be refilled nor checked. In the event of an oil
loss, the mechatronics must be replaced!

2. Clutch 67

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Gearbox 0AM-DSG - Edition 01.2015

– Turn gearbox so that the clutch is facing up.

– Remove the circlip of the hub -arrow-.

– Use the hook - 3438- and a screwdriver to remove the hub.

– Remove the circlip for the clutch -arrow-.
It is possible that the clutch is resting on the circlip so that the

circlip fits very tightly. In this case it is possible to press the clutch
slightly downwards as described in the following work procedure.
In doing so, the circlip is released.

Caution

Do not knock on the clutch or the shaft with a hammer!

• Always replace circlip -arrow-.
Clutch circlip -arrow- cannot be removed

68 Rep. gr.30 - Clutch

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– Position the supporting bridge - T10323- parallel to the flange

of the clutch housing.

– Equalise distances, e.g. using washers -B- with a total thick‐

ness of 15 mm.

– Attach the supporting bridge - T10323- with screws -A- and

secure with nuts.

Caution

Risk of damage to the clutch as well as to other components!
Press the clutch downwards with light force without pressing

it.

– Carefully press the clutch downwards via the spindle.
– Remove supporting bridge - T10323- .

– Remove the circlip for the clutch -arrow-.

• The circlip may not be reused.
Continue after removing the clutch circlip.

Gearbox 0AM-DSG - Edition 01.2015

– Insert the extractor - T10373- in the clutch and remove the

clutch.

– Remove the clutch together with the extractor - T10373- .

2.3 Install double clutch

Special tools and workshop equipment required

2. Clutch 69

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Gearbox 0AM-DSG - Edition 01.2015

♦ Extractor - T10373­♦ Supporting bridge - T10323­♦ Thrust piece - T10368­♦ Thrust piece - T10376­♦ Adhesive - AMV 195 KD1 01-

Caution

When replacing the double clutch, the following parts must al‐
ways be replaced too:

♦ the two engaging levers with engaging bearings
♦ on gearboxes up to production date 05.2011: Bearing of

the engaging lever

♦ on gearboxes as of Production date 06.2011: Ball pin of

the engaging lever for clutch K2

♦ Shims for engaging bearing

After replacing the double clutch and the corresponding parts,
the position of the engaging bearings for clutches K1 and K2
will always require re-adjusting

⇒ “1.3 Adjust clutch release mechanism”, page 41 .

Note

♦

If all the mentioned parts are only removed and reinstalled,
there is nothing to adjust.

♦

The circlip must be replaced under all circumstances.

Caution

Perform adjustment before installing the double clutch.
If not correctly adjusted, do not continue with further installa‐

tion.
Only one adjusting washer may be installed on all bearings.
The parts of the clutch must be installed free of grease and oil!
The clutch is self-adjusting. Vibrations can have a negative ef‐

fect on the adjusting device. Therefore do not let the clutch fall.
Do not let the clutch fall into the gearbox when installing it.
A clutch that has been dropped on a hard surface, or which is

otherwise damaged, must no longer be installed.

• The mechatronics for double clutch gearbox - J743- is installed
on the gearbox

• The clutch release mechanism is installed

⇒ “1.2 Removing and installing clutch release mechanism”,
page 34

– Screw out spindle of the extractor - T10373- .

70 Rep. gr.30 - Clutch

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...

– Position the extractor onto the clutch.
– Insert the clutch with extractor - T10373- into the gearbox and

then remove the extractor.

– Position the supporting bridge - T10323- parallel to the flange

of the clutch housing.

– Equalise distances, e.g. using washers -B- with a total thick‐

ness of 15 mm.

– Secure the supporting bridge - T10323- with screws -A- and

nuts.
– Press the clutch downwards via the spindle as far as it will go.
During press-in procedure, place a hand onto the clutch. A slight

rattling can be felt. Rattling means that the clutch is pressed onto
its press seat. The stop should be felt in this way when the clutch
has reached its seat.

• The clutch is pressed in up to the stop if the circlip can be

inserted.

Gearbox 0AM-DSG - Edition 01.2015

– Hold the circlip with the circlip pliers, as shown in the figure.

• Fitting position of the circlip: The narrower impact side of the

circlip facing upwards.

– Insert the new circlip -arrow-.

2. Clutch 71

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Gearbox 0AM-DSG - Edition 01.2015

– Turn the clutch against the extractor - T10373- by hand so that

the clutch finds its fitting position.

The clutch sits on the input shaft in the bottom part when it is
pressed up to the stop, but this is not the optimum position.

The clutch should only be pulled up until it touches the circlip.

– Only rotate the clutch by hand, and do not use any other tool.

The clutch then slides in place against the circlip.

– Place the hub in position.
The hub has a large tooth and therefore only fits in one position.
On the -engine side-, the large tooth has a marking -arrow-.

– Insert the circlip for the hub -arrow-.

• Install the hub with the marking on the large tooth in such a
way that it is flush with the marking on the drive plate

-arrow-.

• Fitting position: The joint of the ring must point to the hub on
the clutch.

72 Rep. gr.30 - Clutch

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...

– Turn the clutch by hand and, while turning it, pay attention to

the small engaging lever.

• During rotation, there should be no resistance or braking.

• During this process, the engaging lever must remain in its po‐
sition without moving. It must not move up or down -arrows-.

• If any of these events occur when rotating the clutch, the ad‐
justing washers are not seated correctly and the clutch must
be removed again ⇒ “2.2 Remove double clutch”, page 66 .

Gearbox 0AM-DSG - Edition 01.2015

– Check the fitting position of the adjusting washers -arrows-.
♦ Have a close look at the adjusting washers -arrows-.
♦ The adjusting washers must be installed correctly and must

not be damaged.

♦ It is possible that there has been an error in the calculation. In

this case, check the measurement

⇒ “1.3 Adjust clutch release mechanism”, page 41

– Remove the screw plugs and position both ventilation caps

-arrows- again.

Perform the basic setting after the gearbox has been fitted
with the ⇒ Vehicle diagnostic tester.

2. Clutch 73

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Gearbox 0AM-DSG - Edition 01.2015

2.4 Replacing the sealing ring for the outer drive shaft

Special tools and workshop equipment required
♦ Pipe section - MP3-450 (VW 415A)­♦ Extractor tool - T20143­2 shaft seals are located in the gearbox -arrows- on the clutch

side. Both seals can be replaced without disassembling the gear‐
box. If only the shaft seals are replaced, the double clutch must
not be adjusted.

In the event of a gearbox drive shaft “Leaks” error, the condition
of the engine crankshaft sealing flange on the gearbox side must
also be checked.

• Double clutch gearbox removed

⇒ “2.2 Remove double clutch”, page 66

• Clutch release mechanism is removed

⇒ “1.2 Removing and installing clutch release mechanism”,
page 34

Caution

If there are leaks, you must check the double clutch. If the
double clutch is covered in oil, it will need to be replaced.

– Lever out shaft seal for outer drive shaft.

74 Rep. gr.30 - Clutch

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...

– Drive in new shaft seal so that it is flush with the clutch housing.

Use a plastic hammer for this purpose.

• The shoulder -arrow- on the pipe section - MP3-450- points
upwards.

Note

If the inner drive shaft is installed, position the pipe - T30055
(3296)- onto the pipe section - MP3-450- if necessary.

Caution

Touch the gasket ring until flush to ensure the oil bore under‐
neath is not blocked In this case, the bearing is not given a
sufficient supply of oil.

– Install the clutch release mechanism

⇒ “1.2 Removing and installing clutch release mechanism”,
page 34 .

– Install double clutch ⇒ “2.3 Install double clutch”, page 69 .

Gearbox 0AM-DSG - Edition 01.2015

2.5 Replace gasket ring for inner drive shaft

Special tools and workshop equipment required
♦ Gasket ring extractor - T10420­♦ Thrust piece - T10421­2 shaft seals are located in the gearbox -arrows- on the clutch

side. Both seals can be replaced without disassembling the gear‐
box. If only the shaft seals are replaced, the double clutch must
not be adjusted.

In the event of a gearbox drive shaft “Leaks” error, the condition
of the engine crankshaft sealing flange on the gearbox side must
also be checked.

• Double clutch gearbox removed

⇒ “2.2 Remove double clutch”, page 66

• Clutch release mechanism is removed

⇒ “1.2 Removing and installing clutch release mechanism”,
page 34

Caution

If there are leaks, you must check the double clutch. If the
double clutch is covered in oil, it will need to be replaced.

– Release the spindle of the gasket ring extractor - T10420- .

2. Clutch 75

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– Screw in gasket ring extractor for shaft seals - T10420- without

spindle into the small inner shaft sealing ring.

While doing so, press onto the gasket ring extractor for shaft seals

- T10420- .

• Screw sealing ring extractor for shaft sealing ring - T10420- in
until the sealing ring begins to turn in its bearing.

– Next, screw the spindle back into the gasket ring extractor for

shaft seals . If necessary, hold the outer drive shaft while doing
so.

– Remove the shaft seal using the screws on the spindle.

– Drive in the new shaft sealing ring up to the stop of the thrust

piece - T10421- .

Depth of installation of the gasket ring: 17.5 ± 0.2 mm
– Install the clutch release mechanism

⇒ “1.2 Removing and installing clutch release mechanism”,
page 34 .

– Install double clutch ⇒ “2.3 Install double clutch”, page 69 .

76 Rep. gr.30 - Clutch

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...

Gearbox 0AM-DSG - Edition 01.2015

34 – Controls, housing

1 Mechatronics for double clutch gear‐

box - J743-

⇒ “1.1 Summary of components - mechatronics for double clutch
gearbox J743 ”, page 77

⇒ “1.2 Remove mechatronics for double clutch gearbox J743 ;
gearbox installed.”, page 79

⇒ “1.3 Bringing the mechatronics for double clutch gearbox J743
to the removal position by hand”, page 87

⇒ “1.4 Install mechatronics for double clutch gearbox J743 ; gear‐
box installed”, page 89

1.1 Summary of components - mechatronics for double clutch gearbox - J743-

1 - Screw

❑ for attaching the mecha‐

tronics for double clutch
gearbox - J743- at gear‐

box housing
❑ 3 pieces, M8 x 35
❑ Replace after disas‐

sembly
❑ 10 Nm

2 - Screw

❑ for attaching the mecha‐

tronics for double clutch

gearbox - J743- at gear‐

box housing
❑ 4 pieces, M8 x 90
❑ Replace after disas‐

sembly
❑ 10 Nm

3 - Mechatronics for double
clutch gearbox - J743-

❑ The mechatronics is al‐

located according to the

gearbox code letters ⇒

Electronic Catalogue of

Original Parts .
❑ Bring the mechatronics

to removal position by

hand

⇒ “1.3 Bringing the me‐

chatronics for double

clutch gearbox J743 to

the removal position by

hand”, page 87

❑ Remove mechatronics

⇒ “1.2 Remove mecha‐

tronics for double clutch

gearbox J743 ; gearbox installed.”, page 79

❑ Install mechatronics

⇒ “1.4 Install mechatronics for double clutch gearbox J743 ; gearbox installed”, page 89

1. Mechatronics for double clutch gearbox J743 77

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...
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On some transmissions, a cover is present above the engaging
lever.

The cover protects against contamination.

Tightening torque securing bolts: 8 Nm

View of the selector forks of the gearbox when the mechatronics
is removed

N - Neutral
R - Reverse gear
When the reverse gear is en‐

gaged, the extended tappet of
the mechatronics is hooked on
the gearbox housing.

Therefore, the mechatronics
must be put into the removal
position by hand

⇒ “1.3 Bringing the mechatron‐
ics for double clutch gearbox
J743 to the removal position by
hand”, page 87 .

1 - first gear
2 - second gear
3 - third gear
4 - fourth gear
5 - fifth gear
6 - sixth gear
7 - seventh gear

78 Rep. gr.34 - Controls, housing

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...

1.2 Remove mechatronics for double clutch gearbox - J743- ; gearbox installed.

Special tools and workshop equipment required
♦ Assembly lever - T10407­♦ Catch pan - VAS 6208-

WARNING

Follow the safety measures when working on the mechatronics
for double clutch gearbox - J743-

⇒ “2.3 Safety measures for working on the mechatronics for
double clutch gearbox J743 ”, page 2 .

Note

♦

Observe general repair instructions and other instructions for
automatic gearbox DSG - 0AM

⇒ “3 Repair instructions”, page 4 .

♦

The new mechatronics for the gearbox is already precisely fil‐
led with oil at the factory, do not drain the oil.

♦

The removed mechatronics is sent back with oil (close the
ventilation opening with a suitable plug).

♦

Pay attention to the ventilation when handling the mechatron‐
ics .

♦

During assembly work, remove the air bleed valve and close
the opening with a suitable screw plug. In case of oil leakage
from the mechatronics , the mechatronics must be replaced ⇒
Electronic Catalogue of Original Parts .

♦

The clutch is self-adjusting. Vibrations can have a negative
effect on the adjusting device. Even when the mechatronics is
removed, the sudden removal of the assembly lever - T10407­below the engaging levers can have a negative effect on the
adjusting device.

♦

Ensure adequate clearance in front of the gearbox in order to
remove the mechatronics. Components, which are not directly
connected with the gearbox, must be removed on some vehi‐
cles. Any brackets on the screw plugs of the mechatronics
must be removed.

♦

After the battery earth strap is disconnected and connected,
carry out additional operations ⇒ Electrical System; Rep. gr.
27 .

♦

Before removing the mechatronics , basic setting of the neutral
position of the gearbox must be performed ⇒ Vehicle diag‐
nostic tester

Gearbox 0AM-DSG - Edition 01.2015

– Shift selector lever into position P.
– Connect vehicle diagnosis, measurement and information

system - VAS/ODIS- .

– Select Targeted functions .
Under “7-speed double clutch gearbox”, select bring gear ac-

tuator into neutral position.

– Switch off ignition.

1. Mechatronics for double clutch gearbox J743 79

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– Disconnect the battery-earth strap with the ignition off ⇒ Elec‐

trical System; Rep. gr. 27 .

– Remove air filter ⇒ Engine; Rep. gr. 24 or ⇒ Engine; Rep.

gr. 23 .

– Remove battery and battery tray ⇒ Electrical System; Rep.

gr. 27 .

– Removing starter ⇒ Electrical System; Rep. gr. 27 .

Caution

♦ Under no circumstances must the plug contacts in the plug

of the gearbox be touched with the hands, because the
control unit can be destroyed through static discharge as
well as the mechatronics.

– Grab with the hand (without gloves) at the mass, in order to

discharge yourself electrostatically.

– Release the connector catch of the mechatronics by pulling it

in -direction of arrow- and disconnect the plug.

– Unclip the electrical cables from the top bracket at the front of

the gearbox.

Caution

The ventilation cap on the mechatronics is damaged when re‐
moved and must be replaced!

The oil filling in the area with the hydraulic oil for mechatronics
can not be checked. Before assembly work, the ventilation of
the mechatronics must be sealed oil-tight.

The oil escaping from the area with hydraulic oil for mecha‐
tronics cannot be refilled nor checked. In the event of an oil
loss, the mechatronics must be replaced!

– Remove the cover from the ventilation and close the opening

with a suitable screw plug so that no oil can escape.

WARNING

When the engine is warm the cooling system is under pressure.
Slowly open the cap of the coolant expansion tank to first re‐
duce pressure before pulling off the coolant hoses.

– Raise vehicle.
– Remove the sound dampening system ⇒ Body Work; Rep.

gr. 50 .

– Remove the charge air hose from the bottom left charge air

cooler and the charge air pipe ⇒ Engine; Rep. gr. 21 .

– Shut off the opening of the charge air cooler so that no coolant

can penetrate.

Vehicles Octavia II, Superb II, Yeti, Rapid NH

80 Rep. gr.34 - Controls, housing

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...

– Disconnect plug -2- at the coolant temperature sender at ra‐

diator outlet - G83- .

– Place a catch pan for workshop crane - VAS 6208- under the

radiator.

– Remove the bottom coolant hose -1- from the radiator, to do

so raise the retaining clip ⇒ Engine; Rep. gr. 19 .

– Separate the plug connections -1- of the bottom radiator fan

at the fan shroud.

– Screw out screws -arrows- and remove fan shroud with radi‐

ator fans downwards.

Gearbox 0AM-DSG - Edition 01.2015

Fabia II and Roomster vehicles with radiator fan control unit ­J293-

– Unscrew the nuts -3- from the left frame side rail and tie up the

radiator fan control unit - J293- -4-.

• Do not disconnect the plugs -1- and -2-.

Continued for all Fabia II and Roomster vehicles

– Unplug connector -arrow-.

1. Mechatronics for double clutch gearbox J743 81

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– Unclip the fan shroud e.g. using a screwdriver and remove ⇒

Engine; Rep. gr. 19 .

– Place a catch pan for workshop crane - VAS 6208- under the

radiator.

– Remove the bottom coolant hose from the radiator -arrow- and

drain the coolant ⇒ Engine; Rep. gr. 19 .
Continued for all vehicles
– Position the catch pan under the gearbox.

– Release oil drain plug -arrow- at the gearbox.

– Drain off oil.
– Install oil drain plug.

Note

Suction off oil residues which do not escape from the gearbox
after removing the mechatronics with the diesel extractor, e. g. ­VAS 5226- .

82 Rep. gr.34 - Controls, housing

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...

– Where present, remove the cover above the engaging lever.
– Remove the electrical lines from the bottom holder at the front

of the mechatronics and tie up.

– Remove all the brackets from the gearbox.

Gearbox 0AM-DSG - Edition 01.2015

– Carefully unlock the gearbox input r.p.m. sender - G182- with

a screwdriver and pull it out of the housing in the

-direction of arrow-.

1. Mechatronics for double clutch gearbox J743 83

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Gearbox 0AM-DSG - Edition 01.2015

Now both levers of the clutch control must be pressed off the me‐
chatronics with the assembly lever - T10407- . Otherwise the
levers for mechatronics strike the tappets and the mechatronics
cannot be removed.

– Insert the assembly lever - T10407- between the two clutch

engaging levers and the gearbox housing in the

-direction of arrow-.

The assembly lever - T10407- should rest with the complete sur‐
face of the reverse side against the gearbox housing and the
groove should form one level with the recess of the housing

-arrow-.

• Do not insert the assembly lever - T10407- up to the stop.

84 Rep. gr.34 - Controls, housing

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...

– Turn the assembly lever - T10407- to the left in

-direction of arrow- and thus press the engaging lever away
from the tappets.

• Do not remove the assembly lever - T10407- .

If necessary, press the assembly lever - T10407- against the
gearbox using a screwdriver, thereby both levers of the double
clutch gearbox are pressed off the mechatronics .

Gearbox 0AM-DSG - Edition 01.2015

Caution

While doing so, the rubber grommets of the double clutch ad‐
justers should not be damaged.

– Unscrew long screws -B- (4 screws, M8 x 90) crosswise in

stages.

1. Mechatronics for double clutch gearbox J743 85

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– Unscrew short screws -A- (3 screws, M8 x 35) crosswise in

stages.

Caution

Do not remove more than 7 screws!
There are 4 long and 3 short screws.
Do not loosen the screw plugs of the mechatronics .

– Grab with the hand (without gloves) at the mass, in order to

discharge yourself electrostatically.

Caution

♦ Only then touch or remove the mechatronics for double

clutch gearbox - J743- , after you have discharged yourself
electrostatically at an earthed object beforehand, e.g. skin
contact with mass.

♦ Under no circumstances must the plug contacts in the plug

of the gearbox be touched with the hands, because the
control unit can be destroyed through static discharge as
well as the mechatronics.

– Remove mechatronics.

Caution

Place down the removed mechatronics so that no oil is able to
escape through the vent (seal ventilation opening with a suit‐
able plug).

After removing the mechatronics, leave the assembly lever ­T10407- inserted between the engaging levers of the double
clutch and gearbox housing. Removing the assembly lever can
produce negative effects on the automatic adjusting device of
the clutch.

If the double clutch gearbox mechatronics - J743- “is fixed in
place” and cannot be removed

It is possible that the mechatronics cannot be removed if the gear
actuator top left on the gearbox housing jams -arrow-.

Caution

In this case, the mechatronics should not be removed with in‐
creased force.

• The mechatronics must be repositioned at the gearbox hous‐

ing, fixed with a screw, and put into removal position by hand

⇒ “1.3 Bringing the mechatronics for double clutch gearbox

J743 to the removal position by hand”, page 87 .

Removed double clutch gearbox mechatronics - J743- is returned
with oil.

86 Rep. gr.34 - Controls, housing

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...

– Make sure that no oil flows out of the ventilation -arrow- (close

the ventilation opening with a suitable screw plug).

The new double clutch gearbox mechatronics - J743- is filled with
recycled oil.

Install mechatronics on installed gearbox

⇒ “1.4 Install mechatronics for double clutch gearbox J743 ; gear‐
box installed”, page 89 .

1.3 Bringing the mechatronics for double clutch gearbox - J743- to the removal position by hand

Special tools and workshop equipment required
♦ Sealing grease - G 052 128 A1­It is possible that the mechatronics cannot be removed. In this

case, the gear actuator -arrow- jams on the gearbox housing.
If the removal position could not be set with the vehicle diagnosis,

measurement and information system - VAS/ODIS- , the mecha‐
tronics must be brought to the removal position by hand.

The jammed gear actuator must now be pressed by hand into the
removal position. To do so, remove the cover on the gearshift
shaft.

Gearbox installed

• The mechatronics is located in the gearbox housing and is

secured with a screw.
– Shift selector lever into position P.
Vehicles Octavia II, Superb II, Yeti and Rapid NH
– Remove battery and battery tray ⇒ Electrical System; Rep.

gr. 27 (if they were not yet removed).
Vehicles Fabia II and Roomster
– Remove air filter housing complete with air guide hose ⇒ En‐

gine; Rep. gr. 24 .
Continued for all vehicles

Gearbox 0AM-DSG - Edition 01.2015

– Expose the selector lever control cable -A- of the gearbox shift

lever with the removal tool for the inner lining of the door panel

-MP8-602/1- (if it has not yet been removed).

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Gearbox 0AM-DSG - Edition 01.2015

– Remove the lock washer -arrow- of the selector lever control

cable, the selector lever control cable must be left in the fitting
position.

– Carefully push the selector lever control cable to the rear, re‐

move it from the cable support and tie up.

Note

♦

The lock washer -arrow- of the selector lever must always be
replaced.

♦

Do not bend or buckle selector lever control cable.

Gearbox removed

– Press the lever in -direction of arrow- by hand up to the stop

and shift the gearshift lever to position P.

The gearbox is installed or removed

– Remove gearshift lever.
– Remove cover.

Caution

The mechatronics will no longer clamp at the next work step.
This means, it will malfunction under certain circumstances. If
not yet performed, the mechatronics must be secured at the
gearbox with a screw against falling down.

– Push the shift lever to the side through the opening in the

-direction of arrow-.

By doing so, the jammed gear actuator is now pressed back and
the mechatronics can be removed.

– Clean the sealing surface on the gearbox and the cover.
– Grease the shaft seal in the cover with sealing grease - G 052

128 A1- .

Note

Replace the screw of the gearshift lever after removal.

88 Rep. gr.34 - Controls, housing

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...

– Install the cover and the gearshift lever again.
Fill gearbox with gear oil ⇒ “5 Change gearbox oil”, page 174 .
Specified torques

Component Nm
Screw for gearbox shift

lever to gearshift shaft
Screw for gearbox cov‐

er to gearbox

15 Nm

8 Nm

1.4 Install mechatronics for double clutch

gearbox - J743- ; gearbox installed

Special tools and workshop equipment required
♦ Assembly lever - T10407­♦ Guide bolt - T10406­♦ Catch pan for workshop cranes - VAS 6208­♦ Diesel extractor , e. g. -VAS 5226-

Gearbox 0AM-DSG - Edition 01.2015

Caution

In case of oil leakage from the mechatronics, the mechatronics
must be replaced ⇒ Electronic Catalogue of Original Parts .

The new mechatronics for double clutch gearbox - J743- is al‐
ready precisely filled with oil at the factory.

Therefore, it is only possible to fill the mechatronics with oil at
the factory.

Note

♦

The mechatronics for double clutch gearbox - J743- is as‐

signed to the gearbox identification characters ⇒ Electronic

Catalogue of Original Parts .

♦

The removed mechatronics for double clutch gearbox - J743-

is sent back with oil (close the ventilation opening with a

suitable plug).

– If this is not yet the case, close the ventilation with a suitable

screw plug -arrow- so that no oil can flow out.

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Gearbox 0AM-DSG - Edition 01.2015

• Before installing the mechatronics, make sure that no oil is in
the gearbox.

• The assembly lever - T10407- is inserted between the engag‐
ing levers of the double clutch gearbox and the gearbox hous‐
ing.

– Suction off residual oil from the gearbox with diesel suction

device, e. g. -VAS 5226- .

All shift forks have 3 positions:
The centre position is shown in the figure as position -N- (neutral).
No gear is engaged in this position, i.e neutral (neutral position)

is engaged.
– First check all 4 shift forks by hand.
– Consecutively bring all 4 shift forks once into each position

-arrows-, if necessary turn a little on the pinions.

– Then bring all the shift forks back to the centre position, posi‐

tion -N-.

90 Rep. gr.34 - Controls, housing

N - Neutral
R - Reverse gear
1 - first gear
2 - second gear
3 - third gear
4 - fourth gear
5 - fifth gear
6 - sixth gear
7 - seventh gear

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...

Gearbox 0AM-DSG - Edition 01.2015

– Screw in guide bolts - T10406- by hand.

Adjust gear actuator:

Caution

Risk of damage mechatronics for double clutch gearbox ­J743- .

When removing the pins, do not press the senders.

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Gearbox 0AM-DSG - Edition 01.2015

– Set the 4 gear switches on the rear side of the mechatronics

for double clutch gearbox - J743- into the specified position.

Specified position: -a- = 25 mm
– Clean the sealing surface on the gearbox housing on which

the mechatronics will rest at a later stage.

Oil residues on the sealing surface can lead to the wrong diag‐
nosis »leaking« at a later stage.

92 Rep. gr.34 - Controls, housing

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...

• The seal for mechatronics for double clutch gearbox - J743­must be attached all around.

– Check the sender. The clip must not be damaged.
– Install mechatronics.
When handling and installing, make sure that the shift forks are

not unintentionally pressed out of their position. Also pay attention
to the engaging lever and the tappet of the mechatronics.

– Screw in the screws -A- (3 pieces, M8 x 35) and -B- (2 pieces,

M8 x 90) crosswise by hand.

– Remove guide bolts - T10406- .
– Screw in the remaining screws -B- (2 pieces, M8 x 90) by hand.

Gearbox 0AM-DSG - Edition 01.2015

• Make sure that the tappets grip precisely into the engaging
lever bearing. Pull out the tappets by hand until they fit in these
bearings.

– Check the position of the tappets once again.

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Gearbox 0AM-DSG - Edition 01.2015

Incorrectly mounted tappets will damage the mechatronics.
The tappets can be put into their correct positions by means of a

hook made from welding wire.

– Tighten all the screws for the mechatronics for double clutch

gearbox - J743- crosswise to the specified tightening torque.

– Turn the assembly lever - T10407- slowly and carefully to the

right and remove it.

• Both clutch adjusters must correctly lock in the recesses of the
engaging levers of the double clutch.

• While doing so, the rubber grommets of the double clutch ad‐
justers should not be damaged.

• The rubber grommets must rest on the mechatronics.

• An incorrect assembly or damage to the rubber grommets
leads to oil leakage in the mechatronics.

– Position the gearbox input r.p.m. sender - G182- in the

-direction of arrow- on the gearbox housing.

– Check gearbox input r.p.m. sender - G182- . The clip must not

be damaged.

• The gearbox input r.p.m. sender - G182- must be positioned
completely and tightly with its tab on the gearbox housing.

• If the sender is loose, the clip of the mechatronics is broken
must be replaced.

– Remove the screw plug from the ventilation and position the

ventilation cap.

94 Rep. gr.34 - Controls, housing

Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ...

– Install the cover against contamination above the engaging

lever.

Caution

♦ Under no circumstances must the plug contacts in the plug

of the gearbox be touched with the hands, because the
control unit can be destroyed through static discharge as
well as the mechatronics.

– Grab with the hand (without gloves) at the mass, so that it dis‐

charges electrostatically.

– Mount the plug of the mechatronics and lock.
– Reattach all brackets and cables to the gearbox.
– Install fan shroud with fans ⇒ Engine; Rep. gr. 19 .
Vehicles Octavia II, Superb II, Yeti and Rapid NH

Gearbox 0AM-DSG - Edition 01.2015

– Attach the bottom coolant hose -1- at the radiator ⇒ Engine;

Rep. gr. 19 .
– Fit on plug -2- and fill up with coolant ⇒ Engine; Rep. gr. 19 .
– Install charge air hose ⇒ Engine; Rep. gr. 21 .
– Install the noise insulation ⇒ Body Work; Rep. gr. 50 .
– Pour in gear oil ⇒ “5 Change gearbox oil”, page 174 .
– Inspect setting of selector lever control cable; adjust if neces‐

sary

⇒ “2.3 Inspecting and adjusting the selector lever control ca‐

ble”, page 105 .

– Install the battery tray and battery ⇒ Electrical System; Rep.

gr. 27 .
– Install air filter ⇒ Engine; Rep. gr. 24 or ⇒ Engine; Rep. gr.

23 .
After the battery earth strap is disconnected and connected, carry

out additional operations ⇒ Electrical System; Rep. gr. 27 .
– Connect battery ⇒ Electrical System; Rep. gr. 27 .
Vehicles Fabia II and Roomster

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Gearbox 0AM-DSG - Edition 01.2015

– Attach the bottom coolant hose at the radiator -arrow- and fill

up with coolant ⇒ Engine; Rep. gr. 19 .

– If removed, install the radiator fan control unit - J293- on the

left frame side rail.
– Install the noise insulation ⇒ Body Work; Rep. gr. 50 .
– Pour in gear oil ⇒ “5 Change gearbox oil”, page 174 .
– Install the starter motor ⇒ Electrical System; Rep. gr. 27 .
– Install the battery tray and battery ⇒ Electrical System; Rep.

gr. 27 .
After the battery earth strap is disconnected and connected, carry

out additional operations ⇒ Electrical System; Rep. gr. 27 .
– Inspect setting of selector lever control cable; adjust if neces‐

sary

⇒ “2.3 Inspecting and adjusting the selector lever control ca‐

ble”, page 105 .

– Install air filter ⇒ Engine; Rep. gr. 24 .
Continued for all vehicles
After the installation of the mechatronics , perform a basic set-

ting with the ⇒ Vehicle diagnostic tester.

Specified torques

Component Nm
Mechatronics for dou‐

ble clutch gearbox ­J743- on gearbox

Cover to prevent con‐
tamination on gearbox

⇒ “1.1 Summary of components - me‐

chatronics for double clutch gearbox

J743 ”, page 77

8 Nm

96 Rep. gr.34 - Controls, housing