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Service
Workshop Manual
Arteon 2018 ➤ , Passat 2015 ➤ ,
Passat Variant 2015 ➤ , Tiguan 2016 ➤ ,
Tiguan RUS 2017 ➤
7-speed dual clutch gearbox 0DL
Edition 04.2017
Service Department. Technical Information
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List of Workshop Manual Repair Groups
ep ai r Gr ou p
R
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - differential
Service
Technical information should always be available to the foremen and mechanics, because their
careful
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2017 Volkswagen AG, Wolfsburg D4B804A300A
and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
Contents
00 - Technical data
1 Safety information
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 General safety provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 2
1.3 Notes on tow-starting/towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Safety precautions when using testers and measuring instruments during a road test . . . . 2
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 Allocation gearbox - engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.1 Overview of fitting locations - electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
30 - Clutch
1 Clutch
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Assembly overview - dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Removing and installing clutch end cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3 Removing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4 Installing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
34 - Controls, housing
1 Mechatronic unit
1.1 Removing and installing mechatronic unit for dual clutch gearbox J743 (gearbox installed)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2 Removing and installing gearbox input speed sender G182 and oil temperature sender in
2 Bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.1 Distinguishing between different types of bevel boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.2 Removing and installing bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.3 Detaching bevel box from gearbox - gearbox removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.1 Assembly overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.2 Emergency release from position P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.3 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.4 Moving push button in the handle to installation position . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.5 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.6 Removing and installing selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.7 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.8 Checking and adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.9 Renewing oil seal for selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.1 Specified torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.2 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.3 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
5 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
multi-plate clutch G509 up to gearbox date 05/15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Contents i
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
5.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
6 Transporting gearbox
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
7 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
7.1 Assembly overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
8 Installing to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
9 Gear oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
9.1 Removing and installing gear oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
9.2 Removing and installing gear oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
10 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
10.1 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
10.2 Draining and filling gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
35 - Gears, shafts
1 Currently, no repairs can be made to gears and shafts
39 - Final drive - differential
1 Gear oil
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
1.1 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
1.2 Draining and filling gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
2 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
2.1 Overview of fitting locations - seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
2.2 Renewing left oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
2.3 Renewing right oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
3 Components of bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
3.1 Assembly overview - components of bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
3.2 Renewing bevel box seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
3.3 Renewing needle bearing (polygon bearing) for stub shaft . . . . . . . . . . . . . . . . . . . . . . . . 207
ii Contents
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
00 – Technical data
1 Safety information
(VRL010260; Edition 04.2017)
⇒ “1.1 General safety provisions”, page 1
⇒ “1.2 Safety measures when working on vehicles with a start/
stop system”, page 2
⇒ “1.3 Notes on tow-starting/towing”, page 2
⇒ “1.4 Safety precautions when using testers and measuring in‐
struments during a road test”, page 2
1.1 General safety provisions
To prevent personal injury and material damage to the vehicle,
observe the following:
WARNING
Risk of injury and accident by accidental engagement of gear
while engine is running.
♦ Before working on vehicle with engine running, move se‐
lector lever into position “P” and apply handbrake.
To prevent personal injury and damage to or destruction of elec‐
trical and electronic components, observe the following:
♦ Connect and disconnect measuring and testing devices only
with the ignition switched off.
Caution
To prevent damage to the electronic components when dis‐
connecting the battery:
♦ Observe the necessary measures when disconnecting the
battery.
♦ Disconnect battery only after the ignition has been switch‐
ed off.
– Disconnect
Disconnecting and reconnecting battery .
battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
1. Safety information 1
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
1.2 Safety measures when working on ve‐
hicles with a start/stop system
Observe the following when working on vehicles with a start/stop
system:
WARNING
Injury hazard as a result of automatic engine start in vehicles
with start/stop system.
♦ In vehicles with the start/stop system activated (identifia‐
ble by an indication in the dash panel insert) the engine
can start automatically if required.
♦ When working on the vehicle, always make sure that the
start-stop system is deactivated (switch off the ignition;
switch the ignition on again if necessary).
1.3 Notes on tow-starting/towing
Caution
Danger of irreparable damage to gearbox.
♦ If the vehicle must be towed, the selector lever must be in
the
“N” position, and the vehicle must be towed at a speed
no greater than 50 km/h and for a distance not exceeding
50 km.
Note
It is not possible to tow-start the engine, e.g. if the battery is too
flat or the starter is not functioning.
1.4 Safety precautions when using testers
and measuring instruments during a
road test
Observe the following if test and measuring equipment is required
during a road test:
Risk of accident due to distraction and inadequate securing of
test and measuring equipment.
Danger as a result of activation of front passenger airbag in
event of an accident.
• Operation of test and measuring equipment while driving
• Greater injury hazard as a result of unsecured test and
♦ Always strap in place test and measuring equipment on
2 Rep. gr.00 - Technical data
WARNING
results in distraction.
measuring equipment.
rear seat and have a 2nd person sitting on the rear seat
to operate them.
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
Please note the following to avoid personal injury and damage to,
or destruction of, electrical and electronic components:
♦ Connect and disconnect measuring and testing devices only
with the ignition switched off.
Caution
To prevent damage to the electronic components when dis‐
connecting the battery:
♦ Observe the necessary measures when disconnecting the
battery.
♦ Disconnect battery only after the ignition has been switch‐
ed off.
– Disconnect
battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and reconnecting battery .
1. Safety information 3
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
2 Identification
2.1 Gearbox identification
The gearbox code can be found on top of the gearbox, near the
starter.
1 - Gearbox code
2 - Day of production
3 - Month of production
4 - Year of production
5 - Serial number
6 - Minute of production
7 - Hour of production
8 - Factory
Note
The gearbox code is also indicated on the vehicle data stickers.
4 Rep. gr.00 - Technical data
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
3 Repair notes
⇒ “3.1 General information”, page 5
⇒ “3.2 Rules for cleanliness”, page 5
⇒ “3.3 General repair instructions”, page 6
⇒ “3.4 Gaskets and seals”, page 7
⇒ “3.5 Nuts and bolts”, page 7
3.1 General information
Gearbox
♦ The torque of the engine is transmitted via the flywheel to the
dual clutch gearbox. The flywheel and the dual clutch are
joined together by a toothed connection. Together they take
on the function of the dual-mass flywheel.
♦ The gearbox is structured like a manual gearbox. Through op‐
posed
hydraulic actuation of the dual clutch, it is operated like
an automatic gearbox. In other words, the gears are engaged
automatically or manually via the Tiptronic system. There is no
clutch pedal.
Selector mechanism
The feedback for the gearbox concerning the selector lever po‐
sition is not transferred by mechanical means via the selector
lever cable and the multifunction switch (gear sensor) any more,
as is the case for the automatic gearbox. The information con‐
cerning selector lever positions or shifting operations are trans‐
ferred to the gearbox control unit via a separate control unit in the
selector mechanism and the CAN data bus. That is, gears are
shifted without any mechanical cables being involved. Only for
selector lever position “P” the parking lock is engaged mechani‐
cally via the selector lever cable.
Gear change point variations for gradients
An additional gear change map automatically selects gear
changes for gradients dependent upon accelerator pedal position
and driving speed.
• Gear change map for extreme uphill stretches is matched to
engine output.
• Gear change map for extreme downhill stretches is matched
to the braking effect of the engine.
• If a gear is selected directly via the Tiptronic system, it is also
possible to use the braking effect of the engine in a specific
gear, e.g. when driving down a slope with a trailer attached.
3.2 Rules for cleanliness
♦ First thoroughly clean connecting points and surrounding
areas and then loosen bolts.
♦ Seal open lines and connections immediately using clean
plugs or sealing caps from engine bung set - VAS 6122- .
♦ Place removed parts on a clean surface and cover them to
prevent them from getting dirty. Use sheeting and paper for
this purpose. Use lint-free cloths only.
♦ Make sure that no dirt can enter an »open« gearbox.
♦ Install only clean parts; do not remove Genuine parts from
packaging until immediately before installing.
3. Repair notes 5
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
♦ If repair work cannot be performed immediately, cover opened
parts carefully.
♦ Protect disconnected electrical connectors from dirt and water,
and only reconnect them in dry condition.
3.3 General repair instructions
To ensure flawless and successful gearbox repairs, the greatest
care
and cleanliness as well as the use of good and proper tools
are essential. Also note the basic rules on safety when performing
repair procedures.
A number of general notes on the individual repair procedures,
which can otherwise be found in the relevant sections of the man‐
ual, are summarised here. They apply for this particular workshop
manual.
Guided fault-finding, vehicle self-diagnosis and test instruments
♦ Before performing repairs to the gearbox, determine the cause
of the fault as accurately as possible ⇒ Vehicle diagnostic
tester, Guided Fault Finding
or Test Instruments .
Special tool
For a complete list of special tools used in this workshop manual,
see ⇒ "Workshop equipment and special tools" .
Gearbox
Always make sure that no dirt can enter an »open« gearbox. In
particular, dirt entering an »exposed« mechatronic unit for dual
clutch
gearbox - J743- and/or oil pump can lead to gearbox failure.
♦ If gearbox covers have been unbolted or gearbox has no fluid,
do not run engine or tow vehicle.
♦ First thoroughly clean connecting points and surrounding
areas and then loosen bolts.
♦ When installing the gearbox, ensure that dowel sleeves be‐
tween the engine and gearbox are correctly located.
Locking devices
♦ Do not overstretch retaining rings.
♦ Always renew retaining rings which have been damaged or
overstretched.
♦ Retaining rings must locate properly in grooves.
Dual clutch gearbox oil
The oil quality is of critical importance for the function of the gear‐
box.
Shake oil bottle before opening.
Do not mix additives in oil. Do not fill any other oil.
Oil which has been drained out cannot be filled again.
6 Rep. gr.00 - Technical data
, Vehicle Self-Diagnosis
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
Oil drain and inspection plug
A plastic overflow pipe (with 8 mm hexagon socket head) is lo‐
cated behind this plug
-arrow-. Its length determines the oil level
in the gearbox.
3.4 Gaskets and seals
♦ Renew O-rings, seals and gaskets.
♦ After removing gaskets and seals, always inspect contact sur‐
face
of housing or shaft for burrs resulting from removal or for
other signs of damage.
♦ Before installing seals, lightly oil outer diameter and half-fill
space between sealing lips -arrow- with sealing grease G 052 128 A1- .
♦ The open side of the oil seals faces toward the side with fluid
filling.
♦ Only use dual clutch gearbox oil. Other lubricants will cause
problems in function.
♦ Coat O-rings with dual clutch gearbox oil to prevent pinching
of rings during assembly.
♦ After renewing gaskets, O-rings and seals, check oil level in
gearbox and top up if necessary
⇒ page 162 .
3.5 Nuts and bolts
♦ Loosen and tighten securing bolts and securing nut for covers
and housings diagonally.
♦ Specified torques given are for unoiled nuts, bolts and screws.
♦ Clean threads of bolts which are to be installed with locking
fluid using a wire brush. Then insert bolts with locking fluid -
AMV 185 101 A1- .
♦ Use a thread chaser to clear residual locking fluid from all
threaded
Otherwise there is a danger of bolts shearing when subse‐
quently being removed.
♦ Check pitch of thread, to ensure correct thread chaser is used
to clean threads and to ensure the threads are not damaged.
♦ Always renew self-locking bolts and nuts.
holes into which self-locking bolts are to be screwed.
3. Repair notes 7
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
4 Technical data
4.1 Allocation gearbox - engine
4.1.1 Passat 2015 ►, Passat Estate 2015 ►
Take account of the gearbox code if spare parts are required for
a repair.
Dual clutch gearbox 0DL, all-wheel drive
Codes QAX, RCG, SDR QBB, SDM
Engine 2.0 l - 176 kW TDI 2.0 l - 162 kW TSI
4.1.2 Tiguan 2016 ►
Take account of the gearbox code if spare parts are required for
a repair.
Dual clutch gearbox 0DL, all-wheel drive
Codes QAY,
RPN,
Engine 2.0 l - 105,
110
kW TDI
QAY, SDK QBB,
SDK
2.0 l - 130,
140
kW TDI
RPL,
RPP,
SDN
2.0 l - 132,
162 kW
TSI
QBA,
RPM
2.0 l - 176
kW TDI
Dual clutch gearbox 0DL, front-wheel drive
Codes QAZ, RPK
Engine 2.0 l - 110 kW TDI
4.1.3 Arteon 2018 ►
Take account of the gearbox code if spare parts are required for
a repair.
Dual clutch gearbox 0DL, all-wheel drive
Codes RWU
Engine 2.0 l - 176 kW TDI
4.2 Capacities
Initial filling 7.0 l ± 0.1 l
Changing
♦ Change interval: ⇒ Maintenance manual and/
Lubricant Dual clutch gearbox oil
The oil is available as a replacement part; part no. ⇒ Electronic
parts catalogue (ETKA) .
Further information in the part number designates the container
size.
8 Rep. gr.00 - Technical data
Capacity Dual clutch gearbox 0DL
or ⇒ service tables “ELSA”
approx. 5.5 litres
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
Capacity Front bevel box
Capacity of bevel box 0A6
0.9 l
⇒ page 34
Capacity of bevel box 0CP
0.75 l
⇒ page 34
Changing Filled for life, no change
Lubricant Gear oil
The oil is available as a replacement part; part no. ⇒ Electronic
parts catalogue (ETKA) .
Further information in the part number designates the container
size.
4. Technical data 9
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
5 Electrical components
5.1 Overview of fitting locations - electrical components
1 - Mechatronic unit for dual
clutch gearbox - J743-
❑ Removing
⇒ page 26
2
- Gearbox input speed send‐
er - G182- and oil temperature
sender in multi-plate clutch G509-
❑ Both senders are com‐
bined in one component
and can be renewed to‐
gether only.
❑ Removing and installing
⇒ page 32
Before removal of the
❑
sender, the mechatronic
unit for dual clutch gear‐
box - J743- must be re‐
moved
❑ Discontinued
box date 06/15
3 - Selector lever - E313-
❑ With selector lever sen‐
sors control unit - J587- ,
selector lever lock sole‐
noid - N110- and selec‐
tor lever locked in posi‐
tion P switch - F319-
❑ The components are in‐
tegrated into the printed
circuit of the selector
mechanism and cannot
be renewed separately
❑ Checking ⇒ vehicle di‐
agnostic tester
❑ Removing and installing
selector mechanism
10 Rep. gr.00 - Technical data
⇒ page 26 .
and installing
as of gear‐
⇒ page 71
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
30 – Clutch
1 Clutch
⇒ “1.1 Assembly overview - dual clutch”, page 11
⇒ “1.2 Removing and installing clutch end cover”, page 12
⇒ “1.3 Removing dual clutch”, page 15
⇒ “1.4 Installing dual clutch”, page 18
1.1 Assembly overview - dual clutch
Replacement parts
1 - Retaining ring for dual
clutch end cover
❑
Renew after removal
2 - Retaining ring for dual
clutch
❑ Renew after removal
3 - Retaining ring for drive plate
4 - Dual clutch
Caution
♦The drive plate has to re‐
main engaged between
the teeth of the outer
plate carrier.
♦If the drive plate de‐
taches, the plates in the
dual clutch can shift. It
may then not be possible
to adjust the clutch cor‐
rectly when it is installed.
5 - Shims
10 shims having differ‐
❑
ent »thicknesses«.
They are sized in
0.05 mm increments.
❑ Thickness of spacer ring
must be determined
when installing dual
clutch.
6 - Dual clutch end cover
❑ Renew after removal
1. Clutch 11
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
Caution
♦ This figure is intended only to provide an overview of the
components. The dual clutch must not be dismantled be‐
cause all the plates have been balanced relative to each
other.
♦ If the drive plate is detached, the plates in the dual clutch
can
shift, and consequently it may not be possible to adjust
the clutch correctly when it is installed.
1.2 Removing
and installing clutch end cov‐
er
Special tools and workshop equipment required
♦ Clean assembly sleeve - T10459- before using. Do not use a
scratched sleeve.
Brief description
The cover is held in its seat by a retaining ring. After the retaining
ring has been removed, the cover can be levered out of its seat.
Cover and retaining ring must always be renewed. Never install
a
new cover with a hammer and never oil the centre seal or touch
it with a hand! However, if this should happen, the cover is certain
to leak!
Removing
The gearbox must be removed for work on cover.
– Drain gear oil
– Remove gearbox ⇒ page 89 .
– Secure gearbox to assembly stand ⇒ page 157 .
Often, doubts arise as to whether the filter must be renewed or
not.
It is not always necessary to change the oil filter ⇒ page 159 .
12 Rep. gr.30 - Clutch
Note
⇒ page 164 .
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Remove filter if necessary ⇒ page 159 .
– Lever out retaining ring -2- of clutch end cover using screw‐
driver -1- -arrow- and remove.
Cover can be levered out with a screwdriver.
Note
The removed cover and retaining may not be installed again.
Install only a »new« cover.
Installing
Cover and retaining ring must always be renewed.
Never grasp a new cover in centre seal. The centre hole of the
cover
other materials. Leaks will result.
Never install new covers with a hammer!
Caution
must not be touched, oiled or brought into contact with
1. Clutch 13
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Only handle cover as shown -in this picture-.
Note
There must be no stickers on the inside of the cover. If, however,
stickers are present, remove them carefully.
– The running surface on the end of the shaft of the clutch
-arrow- must be free of oil and dry.
– If necessary, thoroughly clean running surface.
WARNING
The centre seal of the new cover must be »preformed« before
installing:
– Clean assembly sleeve - T10459- “before using”. Do not use
a scratched sleeve.
– Set sleeve on a flat surface.
– Guide cover horizontally and evenly over entire sleeve
– Remove sleeve upwards out of cover and set sleeve on end
– Moisten outer seal of cover with oil.
14 Rep. gr.30 - Clutch
-as shown in this figurestallation position.
of clutch shaft.
Caution
Moisten only the outer seal of the cover with oil. Oiling the inner
seal will always cause leaks.
. This will bring the sealing lip into in‐
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Guide
cover horizontally over sleeve and press evenly onto its
seat.
Caution
Work carefully. Any sort of blow to the cover is certain to cause
leaks.
It is possible to lever cover carefully into its seat with a
-screwdriver- until »new« retaining ring can be installed.
– Install new retaining ring.
– Do not remove bush until retaining ring is installed.
– Installing gearbox ⇒ page 146
– Top up gear oil ⇒ page 164 .
WARNING
Do not start engine if there is no oil in gearbox.
1.3 Removing dual clutch
Special tools and workshop equipment required
♦ 2 x hooks - 3438-
1. Clutch 15
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.
Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
♦ Puller - T10055-
♦ Puller - T10525-
Brief description
• The axial play of the clutch is readjusted during installation
procedure.
• To remove or install clutch, gearbox must be securely attached
to an assembly stand in vertical position ⇒ page 157 . Only
this way is it possible later to adjust axial play of the clutch
without error.
Removing
– Remove clutch end cover ⇒ page 12 .
Important! Installation location of drive plate
– Check
ing on the outer plate carrier.
If there is no marking:
– Mark installation position of drive plate relative to periphery of
outer plate carrier with permanent marker, as shown in illus‐
tration.
• During installation, drive plate must always be repositioned at
marked position.
Note
The retaining ring is renewed together with the clutch. If the clutch
which is removed is reinstalled, the securing ring is to be used
again as well.
16 Rep. gr.30 - Clutch
that marking on drive plate -arrow- aligns with the mark‐
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.
Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Lever out retaining ring -2- of drive plate using screwdriver
-1- -arrow-.
– Apply puller - T10525- together with puller - T10055- on
splines and carefully pull drive plate off its seat
-arrows-.
– Remove retaining ring -arrow- and save it for now.
Note
Do not dispose of the retaining ring yet because it will be needed
to measure axial clearance.
1. Clutch 17
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.
Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Remove shim -arrow-.
Caution
Carefully remove the dual clutch. Take care that no parts fall
out. Therefore, do not turn the clutch over!
– Engage 2 hooks - 3438- on opposite sides of clutch -arrow-.
– Remove dual clutch using hooks - 3438- .
1.4 Installing dual clutch
Special tools and workshop equipment required
♦ Universal dial gauge holder - VW 387-
18 Rep. gr.30 - Clutch
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.
Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
♦ Dial gauge - VAS 6079-
♦ Retaining pins - T10524-
7-speed dual clutch gearbox 0DL - Edition 04.2017
♦ Drift sleeve - 40-21-
♦ The drive plate has to remain engaged between the teeth
♦ If the drive plate detaches, the plates in the dual clutch can
♦ Do not lift (not even slightly) or remove plate carrier! The
Brief description
• To remove or install the clutch, the gearbox must be securely
attached to an assembly stand in vertical position.
• The large plate carrier goes through all plates inside the clutch.
It must not slip out of the lowest plate.
Caution
of the outer plate carrier.
shift. It may then not be possible to adjust the clutch cor‐
rectly when it is installed.
plates could turn.
1. Clutch 19
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.
Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
Installing
– Take
great care when removing the dual clutch from its pack‐
age.
– Turn piston rings by hand. They must move freely and must
not bind.
– Ensure that piston rings -1-, -2-, -3- and -4- are seated cor‐
rectly.
The ring butts -arrows- of piston rings -1- and -3- should
align.
– The ring butts -arrows- of piston rings -2- and -4- should align
and be offset 180° to the ring butts of piston rings -1- and -3-.
Important! Position of drive plate
– Before installing, check if there is a marking -arrow- on dual
clutch.
– If
there is no marking, use a permanent marker to make a col‐
our marking on the drive plate and one the outer plate carrier.
– Insert retaining pin - T10524- .
The retaining pin - T10524- should be held by a second mechanic
while the dual clutch is being inserted.
20 Rep. gr.30 - Clutch
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.
Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Carefully insert -dual clutch-, ensuring it does not fall.
– If necessary, insert clutch by turning slightly.
The dual clutch is properly fitted if there is almost no play in the
retaining pin - T10524- .
Note
♦
The retaining pin remains inserted until the clutch end cover
is installed.
♦
The dual clutch must now not be rotated any more, as this can
shift the position of the retaining pin - T10524- .
– Lever out retaining ring -2- of drive plate using screwdriver
-1- -arrow-.
Note
This retaining ring will be used again. Do not dispose of it.
1. Clutch 21
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.
Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Apply puller - T10525- together with puller - T10055- on
splines and carefully pull drive plate off its seat
-arrows-.
Note
The retaining pin - T10524- must be held by a second mechanic
while pulling off.
– Carefully remove drive plate from dual clutch -arrows- and
place it on one side.
Caution
Do not lift (not even slightly) or remove plate carrier! The plates
could turn.
Determining shim for dual clutch:
• The retaining pin - T10524- remains installed!
– Temporarily install “old” retaining ring -arrow-.
Before this ring is finally disposed of, 3 measurements must be
made.
First measurement (axial play of shaft)
– Screw universal dial gauge - VW 387- to gearbox flange.
– Set -tip of dial gauge- on input shaft.
– Set -dial gauge- to 0 with preload.
22 Rep. gr.30 - Clutch
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.
Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Lift dual clutch with force -in direction of arrow- to stop using
hooks - 3438- and note measurement.
– Call this value “A”.
Note
This value will be needed later for the check measurement so
save value “A” until the last measurement has been performed.
Second measurement
• The retaining pin - T10524- remains installed!
– Set tip of dial gauge -on hub of large plate carrier-.
Note
Tip must not sit on retaining ring.
– Set -dial gauge- to 0 with preload again.
– Lift dual clutch with force to stop and note measurement.
– Call this value “B”.
Now calculate which shim must be fitted:
– Use this formula:
Value “B” minus value “A” minus 0.11 = thickness of shim to
be fitted.
– Note result.
The shims are sized in 0.05 mm increments.
– Measure
the shims and determine which one is closest to the
result.
WARNING
Always use the next-largest shim, never the next-smallest.
Example:
Calculated dimension for shim New shim
1.28 mm 1.3 mm
1.26 mm 1.3 mm
– Remove old retaining ring -arrow-.
Note
Do not dispose of ring yet; it will be needed once more.
1. Clutch 23
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Fit calculated shim.
Third measurement (check measurement)
To make sure that the shim is correct, a test measurement must
still be carried out. Proceed as follows:
• The retaining pin - T10524- remains installed!
– Install old retaining ring -arrow- once more.
– Set tip of dial gauge -on hub of large plate carrier-.
Note
Set the tip of the dial gauge on the shim -1-.
– Set -dial gauge- to 0 with preload again.
– Lift dual clutch with force to stop and note measurement.
– Call this value “C”.
Now calculate which shim must finally be fitted:
– Use this formula:
This specification must lie between 0.05 and 0.12 mm.
If the specification is not attained, then achieve the specification
by fitting a thicker or thinner shim.
– Install new retaining ring -arrow-.
24 Rep. gr.30 - Clutch
Value “C” minus value “A” = specification
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Fit drive plate into dual clutch.
• When installing, check if marking on drive plate is aligned with
marking on outer plate carrier
-arrows-. If the markings were
subsequently make, align these.
– A second mechanic must hold retaining pin - T10524- in its
place and press outwards slightly.
– Carefully drive the drive plate onto its seat using press tool -
40-21- and a plastic hammer.
– Install drive plate retaining ring.
– Starting at the opening, press retaining ring in clockwise di‐
rection into its fitting position.
• The retaining ring must be fully engaged.
– Use screwdriver to check that retaining ring is correctly seated
and engaged.
– Now remove retaining pin - T10524- from between dual clutch
and housing.
– Install clutch end cover
⇒ page 12 .
1. Clutch 25
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.
Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
34 – Controls, housing
1 Mechatronic unit
⇒ “1.1 Removing and installing mechatronic unit for dual clutch
gearbox J743 (gearbox installed)”, page 26
⇒ “1.2 Removing and installing gearbox input speed sender G182
and oil temperature sender in multi-plate clutch G509 up to gear‐
box date 05/15”, page 32
1.1 Removing and installing mechatronic
unit for dual clutch gearbox - J743(gearbox installed)
Special tools and workshop equipment required
♦ Up to gearbox date 05/15 release tool - T10465-
♦ Torque wrench - V.A.G 1331-
Always make sure that no dirt can enter an »open« gearbox.
In particular, dirt entering an »exposed« mechatronic unit for dual
clutch gearbox - J743- can lead to gearbox failure.
Please also refer to the notes on the oil filter change regarding
»dirty oil« ⇒ page 159 .
Remove mechatronic unit.
– Move selector lever to position “P”.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
26 Rep. gr.34 - Controls, housing
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
Note
It is possible that parts having nothing to do with the mechatronic
unit must be removed. This depends on the vehicle's equipment.
This will create enough space to remove the mechatronic unit.
Vehicles with petrol engine
– Remove connecting hose between charge air cooler and
charge air pipe ⇒ Rep. gr. 21 ; Charge air system; Assembly
overview - charge air system .
Continued for all vehicles
– Remove electrical wiring and retainer from front of sump
-arrows- (2 x M6 nuts).
– Raise wiring in area of sump and secure it.
– Place
used oil collection and extraction unit - V.A.G 1782- be‐
low gearbox.
– Drain oil
⇒ page 164 .
– Remove securing clip -3-.
– Unscrew bolts -1- diagonally and remove.
– Remove cover -2- with seal.
Always renew bolts, securing clips and the cover with seal.
Note
1. Mechatronic unit 27
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
Before touching mechatronic unit, touch an earthed object again.
To gearbox date 05/15
– Release
connector -1- of gearbox input speed sender - G182and oil temperature sender in multi-plate clutch - G509- using
release tool - T10465- .
Continuation for all:
– Remove bolts -arrows- diagonally.
All 9 bolts have same length and are not allowed to be reused.
28 Rep. gr.34 - Controls, housing
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.
Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Remove mechatronic unit -1- carefully.
Caution
• Lift or put down mechatronic unit only on housing and on
solenoid valves.
Lay mechatronic unit to side properly.
– Put
down mechatronic unit so that sensors -arrows- are point‐
ing upwards.
Install mechatronic unit.
Install in reverse order of removal. During this procedure, observe
the following:
WARNING
Before installing the mechatronic unit, clean the sealing sur‐
face on the gearbox housing thoroughly without using cleaning
agents. Always make sure that no dirt can get into the inside.
To gearbox date 05/15
– Before installation, check that »sender« -1- is installed
⇒ page 32 .
Continuation for all:
1. Mechatronic unit 29
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.
Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
Before touching mechatronic unit, touch an earthed object again.
Caution
• Lift or put down mechatronic unit only on housing and on
solenoid valves.
– Carefully insert mechatronic unit -1- into gearbox.
– Screw in new bolts -arrows- diagonally until finger-tight.
– Tighten bolts in specified sequence to 8 Nm + 45°.
30 Rep. gr.34 - Controls, housing
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.
Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
To gearbox date 05/15
– Push on connector -1- and engage.
– After this, check that fastener -2- is not damaged.
Caution
• Work with great care. The fastener of the connector -2can break. If this has happened, the connector will no
longer hold and the damaged part, e.g. mechatronic unit
for dual clutch gearbox - J743- must be renewed.
Continuation for all:
– Renew seal -arrow-.
A new mechatronic unit already has a new oil seal.
– Moisten seal with oil.
– Set
new cover with seal -2- in place and tighten with new bolts
-1- diagonally in several stages to 10 Nm + 45°.
– Install new securing clip -3-.
– Attach wire retainer to cover and tighten nuts to 10 Nm.
– Push on connector for mechatronic unit for dual clutch gearbox
- J743- and engage lock by turning.
1. Mechatronic unit 31
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Do not start engine!
– Fill with oil ⇒ page 164 .
– Install
noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Assembly overview – noise insula‐
tion .
– Conduct basic adjustment of mechatronic unit for dual clutch
gearbox - J743- .
1.2 Removing and installing gearbox input
speed sender - G182- and oil tempera‐
sender in multi-plate clutch - G509-
ture
up to gearbox date 05/15
Note
♦
As of gearbox date 06/15, the gearbox input speed sender G182- and the oil temperature sender in multi-plate clutch G509- have been discontinued.
♦
If a sender is fitted, a sender must be reinstalled after it has
been removed.
♦
The following procedure applies only to gearboxes in which a
sender is fitted.
Brief description
Both senders are combined in one component and can be re‐
newed together only. They are in the gearbox near the multiclutch. Before removal, the mechatronic unit for dual clutch
gearbox - J743- must be removed.
Removing
– Remove mechatronic unit for dual clutch gearbox - J743-
Do not pull on line!
– Unscrew and remove bolt -2- and pull out sender -1-.
Installing
Install in reverse order of removal. During this procedure, observe
the following:
Reinstall »old« sender only if:
• The sender has no defect
• The cable was not pulled on when it was removed
– Moisten sender with dual clutch gearbox oil and install.
32 Rep. gr.34 - Controls, housing
⇒ page 26 .
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Tighten bolt -2- to 10 Nm.
– Install mechatronic unit for dual clutch gearbox - J743-
⇒ page 26 .
1. Mechatronic unit 33
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
2 Bevel box
⇒ “2.1 Distinguishing between different types of bevel boxes”,
page 34
⇒ “2.2 Removing and installing bevel box”, page 35
⇒ “2.3 Detaching bevel box from gearbox - gearbox removed”,
page 57
2.1 Distinguishing between different types
of bevel boxes
The bevel box installed in the vehicle could be “0A6” or “0CP”.
Bevel boxes can be identified by means of the following:
Distinguishing feature with bevel box installed:
Determine version of bevel box by recess -arrow-
subframe.
Remove following components if necessary:
– Noise insulation ⇒ General body repairs, exterior; Rep. gr.
66 ; Noise insulation .
– Centre underbody cladding ⇒ General body repairs, exterior;
Rep. gr. 66 ; Underbody cladding; Removing and installing
underbody cladding .
in right area of
Area denoted by -arrow- is marked with “0A6” or “0CP”.
Additional distinguishing feature with bevel box removed:
Output flange on bevel box “0A6” is secured with a nut -A- ⇒ As‐
sembly overview - bevel box, “0A6” ⇒ page 186 .
Disregard -B- and -arrows-.
34 Rep. gr.34 - Controls, housing
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
Output flange on bevel box “0CP” is secured with a retaining ring
-A- ⇒ Assembly overview - bevel box, “0CP” ⇒ page 188 .
Located behind retaining ring -A- is a washer -B-.
2.2 Removing and installing bevel box
⇒ “2.2.1 Removing and installing bevel box, Passat 2015 ►, Pas‐
sat Estate 2015 ►, Tiguan 2016 ►, Arteon 2018 ► vehicles with
2.0 l - 176 kW TDI and bi-turbocharger”, page 35
⇒ “2.2.2 Removing and installing bevel box, Passat 2015 ►, Pas‐
sat Estate 2015 ►, vehicles with petrol engine”, page 40
⇒ “2.2.3 Removing and installing bevel box, Tiguan 2016 ►”, page
48
2.2.1 Removing and installing bevel box, Passat 2015 ►, Passat Estate 2015 ►,
Tiguan 2016 ►, Arteon 2018 ► vehicles with 2.0 l - 176 kW TDI and biturbocharger
2. Bevel box 35
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
Special tools and workshop
equipment required
♦ Multi-purpose tool - VW 771-
B-
height.
Note
♦ Hexagon key extension, 8 mm - 3247♦ Supplementary set for engine and gearbox support - VW 540/1
♦ Puller - T 10472Removing
– Raise
After loosening centre bolt, do not lower vehicle to ground again.
36 Rep. gr.34 - Controls, housing
vehicle. All 4 supports of lifting platform must be at same
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
The right drive shaft will be removed in a later step.
– Do
not loosen the front flange bolt -arrow- more than 90° while
the vehicle is still standing on its wheels, or the wheel bearing
will be damaged. ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shaft; Removing and installing drive shaft .
Note
So that the propshaft can be turned later in order to loosen it:
– Move selector lever to »N« position.
– Remove exhaust gas recirculation cooler ⇒ Rep. gr. 26 ; Ex‐
haust gas recirculation; Removing and installing exhaust gas
recirculation cooler .
The engine support - T10533- -A-
remains in the forward position
after the cooler has been removed. This makes it easier to remove
the bevel box later.
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .
– Unscrew bolts -A and B-, and remove gearbox carrier -1- for
bevel box.
– Remove upper securing bolts -arrows- securing bevel box to
gearbox.
2. Bevel box 37
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Loosen lower securing bolts securing bevel box to gearbox
and unscrew only as far as dimension
-a-.
Dimension -a- = 15 mm.
This prevents the bevel box from falling down immediately when
loosened using multi-purpose tool - VW 771- .
– Fit puller - T 10472- to bevel box.
– Prepare
multi-purpose tool - VW 771- with a washer -a- and 2
sleeves from the supplementary set for engine and gearbox
support - VW 540/1 B- as shown in the illustration.
– Bolt multi-purpose tool - VW 771- onto puller - T10472- and
– Remove multi-purpose tool - VW 771- and puller - T10472-
38 Rep. gr.34 - Controls, housing
loosen bevel box from gearbox.
from bevel box.
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Unscrew
lower securing bolts -arrows- and remove bevel box.
Installing
When installing, note the following:
– Grease splines of differential with grease for clutch plate
splines - G 000 100- .
– Install new retaining ring -arrow A- and new O-ring -arrow B-
on right stub shaft.
– Insert
bevel box and press against gearbox as far as it will go.
Note
Turn stub shaft if spline position is unfavourable (bevel box cannot
be pressed to stop against gearbox).
– If splines are correctly positioned and shafts are centred, then
bevel box will slide to stop against gearbox.
Caution
To ensure that the retaining ring of the stub shaft engages
properly in the differential bevel gear, strike the face of the
spline stub with a plastic hammer. Do not pull bevel box force‐
fully against gearbox by turning securing bolts. Damage to
gearbox or bevel box could result.
– Screw on bevel box with new bolts -arrows- until finger-tight,
then tighten. Specified torque: ⇒ page 88 .
2. Bevel box 39
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Unbolt gearbox carrier for bevel box. Observe installation lo‐
cation and tightening sequence of bolts ⇒ page 88 .
– Install exhaust gas recirculation cooler ⇒ Rep. gr. 26 ; Ex‐
haust gas recirculation system; Removing and installing ex‐
haust gas recirculation cooler .
– Install right drive shaft ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Drive shaft; Removing and installing drive shaft .
– Check gear oil in bevel box ⇒ page 170 .
– Following installation, check oil level in gearbox
⇒ page 162 .
– Install
noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation .
Specified torques:
⇒ page 88
2.2.2 Removing and installing bevel box, Passat 2015 ►, Passat Estate 2015 ►,
vehicles with petrol engine
Special tools and workshop
equipment required
♦ Multi-purpose tool - VW 771♦ Hexagon key extension, 8 mm - 3247-
40 Rep. gr.34 - Controls, housing
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
♦ Supplementary set for engine and gearbox support - VW 540/1
B-
♦ Puller - T 10472-
♦ Counter-hold tool - T10172A-
♦ Engine support - T10533-
Removing
– Raise
vehicle. All 4 supports of lifting platform must be at same
height.
Note
After loosening centre bolt, do not lower vehicle to ground again.
The right drive shaft will be removed in a later step.
– Do not loosen the front flange bolt -arrow- more than 90° while
the vehicle is still standing on its wheels, or the wheel bearing
will be damaged. ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shaft; Removing and installing drive shaft .
Note
So that the propshaft can be turned later in order to loosen it:
– Move selector lever to »N« position.
– Remove noise insulation below engine and gearbox. ⇒ Gen‐
eral body repairs, exterior; Rep. gr. 66 ; Noise insulation
2. Bevel box 41
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Disconnect connector -1- from oil level and oil temperature
sender - G266- .
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep.
gr. 40 ; Drive shaft; Removing and installing drive shaft .
– Remove
drive shaft heat shield -1-, if present, from bevel box
(-arrows-) ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive
shaft .
Caution
Risk of damage to decoupling element.
♦ Observe ⇒ Rep. gr. 26 ; Emission control; Assembly
overview - emission control .
– Remove
front exhaust system from engine, raise it and tie it in
place ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Assembly
overview - silencer .
If fitted, remove heat shield for propshaft.
– Unscrew bolts -A- and -B- from bevel box, and remove heat
shield -1-.
– Mark position of propshaft with flexible coupling relative to
output shaft of bevel box -arrows-.
42 Rep. gr.34 - Controls, housing
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Unbolt front propshaft from bevel box -arrows-.
– If
necessary, counterhold at rear final drive when loosening or
tightening propshaft.
Note
To loosen »next« bolt, turn propshaft further by turning rear
wheels at same time.
– Unscrew pendulum support bolts -1- from gearbox.
– Place a cloth on subframe to avoid damaging paint of prop‐
shaft when it is placed on subframe.
– Push font propshaft back to stop. Make sure not to damage
seal -arrow- in centring bush.
2. Bevel box 43
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Guide
propshaft upwards into tunnel, and use a suitable piece
of wood to support it on subframe.
– Set
up engine support - T10533- as shown in figure and tighten
bolts hand-tight.
• -A- thin end
• -B- thick end
Bolt -3- = original pendulum support bolt
– Screw an M 8 x 30 mm bolt -1- with a washer -2- into threaded
hole for noise insulation.
It may be necessary to push the gearbox forwards slightly in order
to attach the engine support - T10533- .
– Force engine/gearbox as far forwards as possible by turning
spindle of engine support - T10533- . Avoid collisions between
components and radiator cowl.
– Unbolt gearbox carrier.
– Unscrew
– Remove upper securing bolts -arrows- securing bevel box to
gearbox.
44 Rep. gr.34 - Controls, housing
bolts -1- and -2-, and remove carrier from bevel box.
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Loosen lower securing bolts securing bevel box to gearbox
and unscrew only as far as dimension
-a-.
Dimension -a- = 15 mm.
This prevents the bevel box from falling down immediately when
loosened using multi-purpose tool - VW 771- .
– Fit puller - T 10472- to bevel box.
– Prepare
multi-purpose tool - VW 771- with a washer -a- and 2
sleeves from the supplementary set for engine and gearbox
support - VW 540/1 B- as shown in the illustration.
– Bolt multi-purpose tool - VW 771- onto puller - T10472- and
loosen bevel box from gearbox.
– Remove multi-purpose tool - VW 771- and puller - T10472-
from bevel box.
2. Bevel box 45
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Unscrew
lower securing bolts -arrows- and remove bevel box.
Installing
When installing, note the following:
– Grease splines of differential with grease for clutch plate
splines - G 000 100- .
– Install new retaining ring -arrow A- and new O-ring -arrow B-
on right stub shaft.
– Insert
bevel box and press against gearbox as far as it will go.
Note
Turn stub shaft if spline position is unfavourable (bevel box cannot
be pressed to stop against gearbox).
– If splines are correctly positioned and shafts are centred, then
bevel box will slide to stop against gearbox.
Caution
To ensure that the retaining ring of the stub shaft engages
properly in the differential bevel gear, strike the face of the
spline stub with a plastic hammer. Do not pull bevel box force‐
fully against gearbox by turning securing bolts. Damage to
gearbox or bevel box could result.
– Screw on bevel box with new bolts -arrows- until finger-tight,
then tighten. Specified torque: ⇒ page 88 .
– Install
ening sequence of bolts
46 Rep. gr.34 - Controls, housing
gearbox carrier. Observe installation location and tight‐
⇒ page 88 .
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Mount drive shaft heat shield -1-, if present, on bevel box
(-arrows-)
⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive
shaft .
– Fit propshaft on bevel box.
Note
When removing and installing the bevel box, do not damage the
seal in the propshaft flange -arrow-. Renew propshaft if damaged.
– Join
bevel box and propshaft by turning spindle of engine sup‐
port - T10533- .
– Remove engine support - T10533- .
– Bolt
– If present, install heat shield for propshaft.
propshaft to bevel box -arrows- ⇒ Rep. gr. 39 ; Propshaft;
Removing and installing propshaft .
2. Bevel box 47
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Version 1:
Version 2:
Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Secure pendulum support to gearbox using new bolts -1-.
Specified torque: ⇒ Rep. gr. 10 ; Assembly mountings; As‐
sembly overview - assembly mountings .
– Install right drive shaft ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Drive shaft; Removing and installing drive shaft .
– Install
parts of exhaust system ⇒ Rep. gr. 26 ; Exhaust pipes/
silencers .
– Check gear oil in bevel box
⇒ page 170 .
– Following installation, check oil level in gearbox
⇒ page 162 .
– Install
Specified torques:
2.2.3 Removing and installing bevel box, Ti‐
The following procedure does not apply to vehicles with bi- tur‐
bocharger.
Removing and installing bevel box - vehicles with 2.0 l - 176 kW
TDI engine and bi-turbocharger
48 Rep. gr.34 - Controls, housing
noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation .
Note
guan 2016 ►
⇒ page 88
⇒ page 35
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
Special tools and workshop
equipment required
7-speed dual clutch gearbox 0DL - Edition 04.2017
B-
♦ Multi-purpose tool - VW 771♦ Hexagon key extension, 8 mm - 3247♦ Supplementary set for engine and gearbox support - VW 540/1
♦ Puller - T 10472-
♦ Counter-hold tool - T10172A-
2. Bevel box 49
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
♦ Engine support - T10533-
Removing
– Raise
vehicle. All 4 supports of lifting platform must be at same
height.
Note
After loosening centre bolt, do not lower vehicle to ground again.
The right drive shaft will be removed in a later step.
– Do not loosen the front flange bolt -arrow- more than 90° while
the vehicle is still standing on its wheels, or the wheel bearing
will be damaged. ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shaft; Removing and installing drive shaft .
Note
So that the propshaft can be turned later in order to loosen it:
– Move selector lever to »N« position.
– Remove noise insulation below engine and gearbox. ⇒ Gen‐
eral body repairs, exterior; Rep. gr. 66 ; Noise insulation
Vehicles with petrol engine:
– Remove connecting hose between charge air cooler and
charge
overview - charge air system .
Vehicles with diesel engine:
50 Rep. gr.34 - Controls, housing
air pipe ⇒ Rep. gr. 21 ; Charge air system; Assembly
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Disconnect connector -1-.
– Unscrew bolt -2- and push auxiliary pump for heating - V488-
to right side. Do not disconnect any lines ⇒ Rep. gr. 19 ;
Coolant pump, regulation of cooling system; Assembly over‐
view - electric coolant pump .
Continued for all vehicles:
– Disconnect connector -1- from oil level and oil temperature
sender - G266- .
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep.
gr. 40 ; Drive shaft; Removing and installing drive shaft .
– Remove
drive shaft heat shield -1-, if present, from bevel box
(-arrows-) ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive
shaft .
Caution
Risk of damage to decoupling element.
♦ Observe ⇒ Rep. gr. 26 ; Emission control; Assembly
overview - emission control .
– Remove
If fitted, remove heat shield for propshaft.
– Unscrew bolts -A- and -B- from bevel box, and remove heat
front exhaust system from engine, raise it and tie it in
place ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Assembly
overview - silencer .
shield -1-.
2. Bevel box 51
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Mark position of propshaft with flexible coupling relative to
output shaft of bevel box -arrows-.
– Unbolt front propshaft from bevel box -arrows-.
– If
necessary, counterhold at rear final drive when loosening or
tightening propshaft.
Note
To loosen »next« bolt, turn propshaft further by turning rear
wheels at same time.
– Unscrew pendulum support bolts -1- from gearbox.
– Place a cloth on subframe to avoid damaging paint of prop‐
52 Rep. gr.34 - Controls, housing
shaft when it is placed on subframe.
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Push font propshaft back to stop. Make sure not to damage
seal -arrow- in centring bush.
– Place
front propshaft on heat shield or on subframe as appro‐
priate.
– Set
up engine support - T10533- as shown in figure and tighten
bolts hand-tight.
• -A- thin end
• -B- thick end
Bolt -3- = original pendulum support bolt
– Screw an M 8 x 30 mm bolt -1- with a washer -2- into threaded
hole for noise insulation.
It may be necessary to push the gearbox forwards slightly in order
to attach the engine support - T10533- .
– Force engine/gearbox as far forwards as possible by turning
spindle of engine support - T10533- . Avoid collisions between
components and radiator cowl.
– Unbolt gearbox carrier for bevel box.
Diesel engine:
– Unscrew bolts -A and B-, and remove gearbox carrier -1- for
bevel box.
Petrol engine:
– Unscrew
Continuation for all:
bolts -1- and -2-, and remove carrier from bevel box.
2. Bevel box 53
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Remove upper securing bolts -arrows- securing bevel box to
gearbox.
– Loosen lower securing bolts securing bevel box to gearbox
and unscrew only as far as dimension
-a-.
Dimension -a- = 15 mm.
This prevents the bevel box from falling down immediately when
loosened using multi-purpose tool - VW 771- .
– Fit puller - T 10472- to bevel box.
– Prepare
54 Rep. gr.34 - Controls, housing
multi-purpose tool - VW 771- with a washer -a- and 2
sleeves from the supplementary set for engine and gearbox
support - VW 540/1 B- as shown in the illustration.
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Bolt multi-purpose tool - VW 771- onto puller - T10472- and
loosen bevel box from gearbox.
– Remove multi-purpose tool - VW 771- and puller - T10472-
from bevel box.
– Unscrew
lower securing bolts -arrows- and remove bevel box.
Installing
When installing, note the following:
– Grease splines of differential with grease for clutch plate
splines - G 000 100- .
– Install new retaining ring -arrow A- and new O-ring -arrow B-
on right stub shaft.
– Insert
bevel box and press against gearbox as far as it will go.
Note
Turn stub shaft if spline position is unfavourable (bevel box cannot
be pressed to stop against gearbox).
– If splines are correctly positioned and shafts are centred, then
bevel box will slide to stop against gearbox.
To ensure that the retaining ring of the stub shaft engages
properly in the differential bevel gear, strike the face of the
spline stub with a plastic hammer. Do not pull bevel box force‐
fully against gearbox by turning securing bolts. Damage to
gearbox or bevel box could result.
Caution
2. Bevel box 55
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Screw on bevel box with new bolts -arrows- until finger-tight,
then tighten. Specified torque: ⇒ page 88 .
– Unbolt gearbox carrier for bevel box. Observe installation lo‐
cation and tightening sequence of bolts ⇒ page 88 .
– Mount drive shaft heat shield -1-, if present, on bevel box
(-arrows-)
⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive
shaft .
– Fit propshaft on bevel box.
Note
When removing and installing the bevel box, do not damage the
seal in the propshaft flange -arrow-. Renew propshaft if damaged.
– Join
port - T10533- . Take note of seal in propshaft flange when
doing this.
– Remove engine support - T10533- .
56 Rep. gr.34 - Controls, housing
bevel box and propshaft by turning spindle of engine sup‐
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Bolt
propshaft to bevel box -arrows- ⇒ Rep. gr. 39 ; Propshaft;
Removing and installing propshaft .
– If present, install heat shield for propshaft.
– Secure pendulum support to gearbox using new bolts -1-.
Specified torque: ⇒ Rep. gr. 10 ; Assembly mountings; As‐
sembly overview - assembly mountings .
– Install right drive shaft ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Drive shaft; Removing and installing drive shaft .
– Install
parts of exhaust system ⇒ Rep. gr. 26 ; Exhaust pipes/
silencers .
Continue installation in reverse order of removal.
– Check gear oil in bevel box
– Following installation, check oil level in gearbox
⇒ page 162 .
– Install
gr. 66 ; Noise insulation .
Specified torques:
2.3 Detaching bevel box from gearbox -
Special tools and workshop equipment required
noise insulation ⇒ General body repairs, exterior; Rep.
⇒ page 88
gearbox removed
⇒ page 170 .
2. Bevel box 57
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
♦ Multi-purpose tool - VW 771-
♦ Hexagon key extension, 8 mm - 3247-
♦ Puller - T 10472-
Removing
– Remove gearbox with bevel box ⇒ page 89 .
– Secure gearbox with bevel box to assembly stand
⇒ page 157 .
In the following illustrations the bevel box is shown in installed
condition.
– Remove upper securing bolts -arrows- securing bevel box to
gearbox.
58 Rep. gr.34 - Controls, housing
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Loosen lower securing bolts securing bevel box to gearbox
and unscrew only as far as dimension
-a-.
Dimension -a- = 15 mm.
This prevents the bevel box from falling down immediately when
loosened using multi-purpose tool - VW 771- .
– Fit puller - T 10472- to bevel box.
– Bolt multi-purpose tool - VW 771- onto puller T10472 and
loosen bevel box from gearbox.
– Unscrew
Installing
When installing, note the following:
lower securing bolts -arrows- and remove bevel box.
2. Bevel box 59
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Grease splines of differential with grease for clutch plate
splines - G 000 100- .
– Install new retaining ring -arrow A- and new O-ring -arrow B-
on right stub shaft.
– Insert bevel box and press against gearbox.
Note
Turn stub shaft if spline position is unfavourable (bevel box cannot
be pressed to stop against gearbox).
– If splines are correctly positioned and shafts are centred, then
bevel box will slide against contact surface on gearbox.
Caution
Retaining ring on stub shaft must engage correctly in differen‐
tial bevel gear. If retaining ring is not engaged, there is a risk
that stub shaft might move outwards.
Also, bevel box is not allowed to be bolted onto gearbox force‐
fully.
Damage to gearbox or bevel box could result in both
cases.
– To ensure that the retaining ring engages properly in the dif‐
ferential bevel gear, strike the face of the spline stub several
times with a plastic hammer (weight 1000 - 2000 g).
– Screw on bevel box with new bolts -arrows- until finger-tight,
then tighten. Specified torque: ⇒ page 88 .
– Installing gearbox ⇒ page 146
– After installing gearbox, check oil level and top up
⇒ page 162 .
60 Rep. gr.34 - Controls, housing
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
3 Selector mechanism
⇒ “3.1 Assembly overview - selector mechanism”, page 61
⇒ “3.2 Emergency release from position P”, page 64
⇒ “3.3 Removing and installing selector lever handle”,
page 65
⇒ “3.4 Moving push button in the handle to installation position”,
page 70
⇒ “3.5 Removing and installing selector mechanism”, page 71
⇒ “3.6 Removing and installing selector lever cable”, page 78
⇒ “3.7 Checking selector mechanism”, page 83
⇒ “3.8 Checking and adjusting selector lever cable”, page 83
⇒ “3.9 Renewing oil seal for selector shaft”, page 85
3.1 Assembly overview - selector mecha‐
nism
⇒ “3.1.1 Assembly overview- selector mechanism, Passat 2015
►, Passat Estate 2015 ►, Arteon 2018 ►”, page 61
⇒ “3.1.2 Assembly overview- selector mechanism, Tiguan 2016
►”, page 63
3.1.1 Assembly overview- selector mechanism, Passat 2015 ►, Passat Estate
2015 ►, Arteon 2018 ►
3. Selector mechanism 61
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
1 - Handle with selector cover
❑
Do not remove handle
without reason. For
emergency release, on‐
ly the cover needs to be
unclipped
❑ Removing
⇒ page 64 .
and installing
⇒ page 65
2 - Bolt
❑
Qty. 4
❑ 8 Nm
3 - Selector mechanism
❑ With integrated selector
lever sensor control unit
- J587- with selector lev‐
er - E313- , Tiptronic
switch - F189- , switch
for selector lever locked
in P - F319- and selector
lever lock solenoid N110-
❑ Removing and installing
⇒ page 71
4 - Selector lever cable
Selector lever cable is
❑
not greased
❑ Removing and installing
⇒ page 78
Checking
❑
Adjusting
❑
⇒ page 83
⇒ page 83
5 - Securing clip
Renew after removal
❑
6 - Hexagon flange nut
❑ Qty. 4
❑ 8 Nm
7 - Selector housing
8 - Cover
9 - Bolt
10 - Gearbox
11 - Bolt
62 Rep. gr.34 - Controls, housing
❑ Renew after removal
❑ Renew after removal
❑ For selector cable support bracket to gearbox
❑ Qty. 2
❑ 20 Nm + 90°
❑ Adjuster screw for selector lever cable
❑ 13 Nm
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
3.1.2 Assembly overview- selector mechanism, Tiguan 2016 ►
1 - Handle with selector cover
❑ Removing
⇒ page 65
2 - Selector mechanism
❑
With integrated selector
lever sensor control unit
- J587- with selector lev‐
er - E313- , Tiptronic
switch - F189- , switch
for selector lever locked
in P - F319- and selector
lever lock solenoid N110-
❑ Removing and installing
⇒ page 71
3 - Bolt
Qty. 4
❑
❑ 8 Nm
4 - Plug
5 - Hexagon flange nut
❑ Qty. 4
❑ 8 Nm
6 - Selector housing
7 - Gearbox
8 - Bolt
❑ Always renew after re‐
moving.
❑ For selector cable sup‐
port bracket to gearbox
❑ Qty. 2
❑ 20 Nm + 90°
9 - Bolt
❑ Adjuster screw for selector lever cable
❑ 13 Nm
10 - Securing clip
❑ Always renew after removing.
❑ Installation position: offset side points forwards towards front end.
11 - Selector lever cable
❑ Selector lever cable is not greased
❑ Removing and installing
❑
Checking and adjusting
and installing
⇒ page 80
⇒ page 83
3. Selector mechanism 63
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
3.2 Emergency release from position P
⇒ “3.2.1 Emergency release from position P, Passat 2015 ►, Pas‐
sat Estate 2015 ►, Arteon 2018 ►”, page 64
⇒ “3.2.2 Emergency release from position P, Tiguan 2016 ►”,
page 64
3.2.1 Emergency release from position P,
Passat 2015 ►, Passat Estate 2015 ►,
Arteon 2018 ►
Do not remove handle
– Depress brake pedal or set handbrake.
– Open lid of storage compartment.
– Grasp under selector lever cover with one hand, and unclip
cover by pulling it upwards.
– Push selector cover to one side.
– Using
a screw driver, from right side, press yellow plastic part
and hold in this position.
Selector lever can now be moved from position »P«.
3.2.2 Emergency release from position P, Ti‐
Special tools and workshop equipment required
♦ -T10383/2-
64 Rep. gr.34 - Controls, housing
guan 2016 ►
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
Do not remove handle
– Depress brake pedal or set handbrake.
– Fit wedge - T10383/2- at front between centre console and
selector cover, and lever selector cover off centre console by
carefully pushing wedge downwards.
– Push selector cover to one side.
– Push yellow plastic lever backwards in direction of arrow and
hold in this position.
Selector lever can now be moved from position »P«.
3.3 Removing and installing selector lever
handle
⇒ “3.3.1 Removing and installing selector lever handle, Passat
2015 ►, Passat Estate 2015 ►, Arteon 2018 ►”, page 65
⇒ “3.3.2 Removing and installing selector lever handle, Tiguan
2016 ►”, page 67
3.3.1 Removing and installing selector lever
Special tools and workshop equipment required
♦ Hose clip pliers - V.A.G 1275-
Brief description
Handle is removed together with selector cover.
handle, Passat 2015 ►, Passat Estate
2015 ►, Arteon 2018 ►
3. Selector mechanism 65
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
Removing
– Shift selector lever to position “D”.
The push button -arrow-
does not need to be pulled out by hand.
Push button engages automatically in installation position when
handle is pulled off.
– Open lid of storage compartment.
– Grasp under selector lever cover with one hand, and unclip
cover by pulling it upwards.
– Disconnect electrical connector.
– Cut open clamp -arrow- under boot using side cutters.
– Pull handle upwards off selector lever without pressing push
button.
Note
Do not press button again after removal as it will no longer be
possible to install the handle.
Installing
Install in reverse order of removal, observing the following:
• Selector lever is in position “D”.
66 Rep. gr.34 - Controls, housing
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Note
Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
♦
There is a chance that the button could be pressed into the
handle. Never install a handle with the button pressed in.
♦
Move push button to installation position ⇒ page 70 .
♦
New handle is supplied with installation guard. Do not remove
guard until just before installing. To remove, pull out
-in direction of arrow-.
– Push
on handle with new clamp -arrow- to stop. Do not tighten
clamp yet.
– Press push button after installation.
Note
If not installed correctly, the button remains inserted in the handle
after being pressed. If this happens, pull handle off again and
move push button to installation position again ⇒ page 70 . Then
fit the handle again.
– If the press button moves back to its start position, the clamp
can be tightened using the hose clip pliers - V.A.G 1275- .
– Connect electrical connector.
– Clip cover in position.
3.3.2 Removing and installing selector lever
handle, Tiguan 2016 ►
Special tools and workshop equipment required
3. Selector mechanism 67
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.
Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
♦ Hose clip pliers - V.A.G 1275-
♦ -T10383/2-
Brief description
Handle is removed together with selector cover.
Removing
– Shift selector lever to position “D”.
The push button -arrow-
does not need to be pulled out by hand.
Push button engages automatically in installation position when
handle is pulled off.
– Fit wedge - T10383/2- at front between centre console and
selector cover, and lever selector cover off centre console by
carefully pushing wedge downwards.
– Disconnect electrical connector.
68 Rep. gr.34 - Controls, housing
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.
Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Cut open clamp -arrow- under boot using side cutters.
– Pull handle upwards off selector lever without pressing push
button.
Note
Do not press button again after removal as it will no longer be
possible to install the handle.
Installing
Install in reverse order of removal, observing the following:
• Selector lever is in position “D”.
Note
♦
There is a chance that the button could be pressed into the
handle. Never install a handle with the button pressed in.
♦
Move push button to installation position ⇒ page 70 .
♦
New handle is supplied with installation guard. Do not remove
guard until just before installing. To remove, pull out
-in direction of arrow-.
3. Selector mechanism 69
P
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.
Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Push
on handle with new clamp -arrow- to stop. Do not tighten
clamp yet.
– Press push button after installation.
Note
If not installed correctly, the button remains inserted in the handle
after being pressed. If this happens, pull handle off again and
move push button to installation position again ⇒ page 70 . Then
fit the handle again.
– If the press button moves back to its start position, the clamp
can be tightened using the hose clip pliers - V.A.G 1275- .
– Connect electrical connector.
– Clip cover in position.
3.4 Moving push button in the handle to in‐
stallation position
If the button was pressed by mistake, the installation position can
be restored.
There are 2 ways of moving the push button into the installation
position,
described here.
Place handle »with« installation guard in installation position:
When using the installation guard, make sure that it has an eyelet
-arrow- at the front. Other types of installation guard are not suit‐
able.
»with« and »without« installation guard. Both of them are
– Holding down push button, completely push in installation
guard
with eyelet -arrow- until installation guard engages, then
release push button. When the installation guard is pulled out,
the push button engages in the installation position.
Place handle »without« installation guard in installation position:
70 Rep. gr.34 - Controls, housing
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Carefully unclip handle trim -A- upwards.
– Using e.g. a screwdriver press small lever -1- for pull rod into
groove -2-. This action presses the push button
-3- back into
installation position.
-I- = button pressed in
-II- = button in installation position
Note
♦
Press the lever only into the groove and no further.
♦
Do not clip the handle trim onto selector mechanism until the
handle has been fitted. This makes it possible to check wheth‐
er the small lever engages in the pull rod when the button is
pressed.
3.5 Removing and installing selector mech‐
⇒ “3.5.1 Removing and installing selector mechanism with selec‐
tor lever cable”, page 71
⇒ “3.5.2 Removing and installing selector mechanism without se‐
lector lever cable, Passat 2015 ►, Passat Estate 2015 ►, Arteon
2018 ►”, page 73
⇒ “3.5.3 Removing and installing selector mechanism without se‐
lector lever cable, Tiguan 2016 ►”, page 75
3.5.1 Removing and installing selector mech‐
Brief description
In the interior, the centre console must be removed.
The heat shield beneath the vehicle must be removed.
Removing
– Remove selector lever handle ⇒ page 65 .
– Remove
repairs, interior; Rep. gr. 68 ; Centre console; Assembly over‐
view - centre console .
anism
anism with selector lever cable
centre console with securing bracket ⇒ General body
3. Selector mechanism 71
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Remove
footwell air duct ⇒ Heating, air conditioning; Rep. gr.
87 ; Air duct; Assembly overview - air routing and air distribu‐
tion in passenger compartment .
– Separate electrical connector from selector mechanism to ve‐
hicle wiring harness.
– Remove air filter housing.
Passat, Tiguan with diesel engine
– ⇒ Rep. gr. 23 ; Air filter; Removing and installing air filter
housing
Tiguan with petrol engine
– ⇒ Rep. gr. 24 ; Air filter; Removing and installing air filter
housing
Continuation for all:
– Pry selector lever cable -arrow- off lever using an open-ended
spanner.
Caution
Locks on selector lever cable break off very easily. If a locking
lug has broken off, complete selector mechanism with selector
lever cable must be renewed.
– Carefully
push locking mechanisms of selector lever cable to‐
gether -arrows- and remove selector lever cable upwards out
of cable support bracket.
– Do not bend or kink cable.
– Remove propshaft on all-wheel drive model ⇒ Rep. gr. 39 ;
Propshaft; Removing and installing propshaft .
– Install centre tunnel heat shield below selector mechanism ⇒
General body repairs, exterior; Rep. gr. 66 ; Mouldings/trims/
extensions; Removing and installing floor heat shield .
72 Rep. gr.34 - Controls, housing
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– If fitted, remove bracket -A-.
– Remove nuts -arrows- inside vehicle.
– Remove selector mechanism -B- together with selector lever
cable and selector housing downwards.
Installing
Install in reverse order of removal. During this procedure, observe
the following:
Note
♦
Do not bend or kink gear selector cable.
♦
Do not grease selector lever cable.
♦
Following installation of selector mechanism, selector lever
cable must be checked for ease of movement and be adjusted.
– Install heat shield below selector mechanism ⇒ General body
repairs, exterior; Rep. gr. 66 ; Mouldings/trims/extensions;
Removing and installing floor heat shield .
– Install propshaft on all-wheel drive model ⇒ Rep. gr. 39 ;
Propshaft; Removing and installing propshaft .
– Install footwell air duct ⇒ Heating, air conditioning; Rep. gr.
87 ; Air duct; Assembly overview - air routing and air distribu‐
tion in passenger compartment .
– Install centre console securing bracket and centre console ⇒
General body repairs, interior; Rep. gr. 68 ; Centre console;
Assembly overview - centre console .
– Install selector lever handle
⇒ page 65 .
– Adjust selector lever cable ⇒ page 83 .
– Check selector mechanism ⇒ page 83 .
– Install air filter housing.
Passat, Tiguan with diesel engine
– ⇒ Rep. gr. 23 ; Air filter; Removing and installing air filter
Tiguan with petrol engine
– ⇒ Rep. gr. 24 ; Air filter; Removing and installing air filter
Specified torques
♦ Selector housing to body
3.5.2 Removing and installing selector mech‐
Brief description
In the interior, the centre console must be removed.
The heat shield beneath the vehicle must be removed.
housing
housing
⇒ “3.1 Assembly overview - selector mechanism”, page 61
anism
sat 2015 ►, Passat Estate 2015 ►,
Arteon 2018 ►
without selector lever cable, Pas‐
3. Selector mechanism 73
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
Removing
– Remove selector lever handle ⇒ page 65 .
– Remove
centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; Centre console; Removing and installing centre con‐
sole .
– Remove centre console vent ⇒ Heating, air conditioning; Rep.
gr. 87 ; Air duct; Assembly overview - air routing and air dis‐
tribution in passenger compartment .
– Remove mounting bracket for centre console ⇒ General body
repairs, interior; Rep. gr. 68 ; Centre console; Removing and
installing centre console .
– Separate electrical connector from selector mechanism to ve‐
hicle wiring harness.
– Shift selector lever on selector mechanism to position “N”.
– Install centre tunnel heat shield below selector mechanism ⇒
General body repairs, exterior; Rep. gr. 66 ; Mouldings/trims/
extensions; Removing and installing floor heat shield .
– Using a screwdriver lever the cover off from under the selector
mechanism -arrow-.
Note
It is not permissible to reuse the cover. Always renew after re‐
moving.
– Release the cable as shown with a screwdriver, and pull off
from the selector lever -arrows-.
– Remove securing clip -arrow-.
Always renew securing clip.
– Pull selector lever cable out of selector mechanism.
74 Rep. gr.34 - Controls, housing
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– If fitted, remove bracket -A-.
– Remove nuts -arrows- inside vehicle.
– Remove
selector mechanism -B- together with selector hous‐
ing downwards.
Installing
Install in reverse order of removal. During this procedure, observe
the following:
Note
♦
Do not bend or kink gear selector cable.
♦
Do not grease selector lever cable.
♦
Following installation of selector mechanism, selector lever
cable must be checked for ease of movement and be adjusted.
• Selector lever on selector mechanism must be set to position
“N”.
– Insert cable into selector mechanism, attach to selector lever
and fit new securing clip.
– Install heat shield below selector mechanism ⇒ General body
repairs, exterior; Rep. gr. 66 ; Mouldings/trims/extensions;
Removing and installing floor heat shield .
– Install mounting bracket ⇒ General body repairs, interior; Rep.
gr. 68 ; Centre console; Removing and installing centre con‐
sole .
– Install centre console vent ⇒ Heating, air conditioning; Rep.
gr. 87 ; Air duct; Assembly overview - air routing and air dis‐
tribution in passenger compartment .
– Install centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; Centre console; Removing and installing centre con‐
sole .
– Install selector lever handle
– Adjust selector lever cable ⇒ page 83 .
– Check selector mechanism ⇒ page 83 .
Specified torques
♦ Selector housing to body ⇒ page 61
3.5.3 Removing and installing selector mech‐
Brief description
In the interior, the centre console must be removed.
The heat shield beneath the vehicle must be removed.
Removing
– Remove selector lever handle ⇒ page 65 .
– Remove
gr. 68 ; Centre console; Removing and installing centre con‐
sole .
anism without selector lever cable, Ti‐
guan 2016 ►
centre console ⇒ General body repairs, interior; Rep.
⇒ page 65 .
3. Selector mechanism 75
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– If fitted, remove footwell air duct ⇒ Heating, air conditioning;
Rep.
gr. 87 ; Air duct; Assembly overview - air routing and air
distribution in passenger compartment .
– If fitted, remove mounting bracket -2-. To do this, unscrew
bolts -1- on right and left.
– Separate electrical connector from selector mechanism to ve‐
hicle wiring harness.
– Shift selector lever on selector mechanism to position “N”. On‐
ly in this position the selector lever cable can be released.
– Install centre tunnel heat shield below selector mechanism ⇒
General body repairs, exterior; Rep. gr. 66 ; Mouldings/trims/
extensions; Removing and installing floor heat shield .
– Remove plug and securing clip -arrow-.
Always renew securing clip.
– Fit
a large screwdriver in grooves of locking element and turn
it 90° in direction of arrow.
– Pull selector lever cable out of selector mechanism.
76 Rep. gr.34 - Controls, housing
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– If fitted, remove bracket -A-.
– Remove nuts -arrows- inside vehicle.
– Remove
selector mechanism -B- together with selector hous‐
ing downwards.
Installing
Install in reverse order of removal. During this procedure, observe
the following:
Note
♦
Do not bend or kink gear selector cable.
♦
Do not grease selector lever cable.
♦
Following installation of selector mechanism, selector lever
cable must be checked for ease of movement and be adjusted.
• Selector lever on selector mechanism must be set to position
“N”. Only in this position the selector lever cable can be en‐
gaged.
– Insert selector lever cable into selector mechanism until it is
visible in locking mechanism
-arrow-.
– With
– The selector lever cable is properly engaged when the
a large screwdriver, turn locking element 90° in direction
of arrow.
grooves in the locking element are at right angles to the se‐
lector lever cable.
3. Selector mechanism 77
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Install new securing clip -arrow- and insert plug.
– Install
heat shield below selector mechanism ⇒ General body
repairs, exterior; Rep. gr. 66 ; Mouldings/trims/extensions;
Removing and installing floor heat shield .
– If
previously removed, install mounting bracket -2- ⇒ General
body repairs, interior; Rep. gr. 68 ; Centre console; Removing
and installing centre console .
– If featured, install footwell air duct ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air duct; Assembly overview - air routing and air
distribution in passenger compartment .
– Install centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; Centre console; Removing and installing centre con‐
sole .
– Install selector lever handle
⇒ page 65 .
– Adjust selector lever cable ⇒ page 83 .
– Check selector mechanism ⇒ page 83 .
Specified torques
♦ Selector housing to body ⇒ page 63
3.6 Removing and installing selector lever
cable
⇒ “3.6.1 Removing and installing selector lever cable, Passat
2015 ►, Passat Estate 2015 ►, Arteon 2018 ►”, page 78
⇒ “3.6.2 Removing and installing selector lever cable, Tiguan
2016 ►”, page 80
3.6.1 Removing and installing selector lever
Removing
Diesel engine
– Remove
and installing air filter housing
78 Rep. gr.34 - Controls, housing
cable, Passat 2015 ►, Passat Estate
2015 ►, Arteon 2018 ►
air filter housing ⇒ Rep. gr. 23 ; Air filter; Removing
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
Continuation for all:
– Pry
selector lever cable -arrow- off lever using an open-ended
spanner.
Caution
Locks on selector lever cable break off very easily. If a locking
lug has broken off, complete selector mechanism with selector
lever cable must be renewed.
– Carefully
push locking mechanisms of selector lever cable to‐
gether -arrows- and remove selector lever cable upwards out
of cable support bracket.
– Do not bend or kink cable.
– Shift selector lever on selector mechanism to position “N”. On‐
ly in this position the selector lever cable can be released.
– Remove parts of ⇒ exhaust system; Rep. gr. 26 .
– Remove propshaft on all-wheel drive model ⇒ Rep. gr. 39 ;
Propshaft; Removing and installing propshaft .
– Install centre tunnel heat shield below selector mechanism ⇒
General body repairs, exterior; Rep. gr. 66 ; Mouldings/trims/
extensions; Removing and installing floor heat shield .
– Using
a screwdriver lever the cover off from under the selector
mechanism -arrow-.
Note
It is not permissible to reuse the cover. Always renew after re‐
moving.
– Release the cable as shown with a screwdriver, and pull off
from the selector lever -arrows-.
3. Selector mechanism 79
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Remove securing clip -arrow-.
Always renew securing clip.
– Pull cable out of selector mechanism and remove.
Installing
Install in reverse order of removal. During this procedure, observe
the following:
Note
♦
Do not bend or kink gear selector cable.
♦
Do not grease selector lever cable.
♦
Following installation, selector lever cable must be checked
for ease of movement and be adjusted.
• Selector lever on selector mechanism must be set to position
“N”.
– Install heat shield below selector mechanism ⇒ General body
repairs, exterior; Rep. gr. 66 ; Mouldings/trims/extensions;
Removing and installing floor heat shield .
– Install propshaft on all-wheel drive model ⇒ Rep. gr. 39 ;
Propshaft; Removing and installing propshaft .
– Check and adjust selector lever cable
⇒ page 83 .
– Check selector mechanism ⇒ page 83 .
Diesel engine:
– Install air filter housing ⇒ Rep. gr. 23 ; Air filter; Removing
and installing air filter housing .
Continue installation in reverse order of removal.
3.6.2 Removing and installing selector lever
cable, Tiguan 2016 ►
Removing
Diesel engine
– ⇒ Rep. gr. 23 ; Air filter; Removing and installing air filter
Vehicles with petrol engine
– ⇒ Rep. gr. 24 ; Air filter; Removing and installing air filter
80 Rep. gr.34 - Controls, housing
housing
housing
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
Continuation for all:
– Pry
selector lever cable -arrow- off lever using an open-ended
spanner.
Caution
Locks on selector lever cable break off very easily. If a locking
lug has broken off, complete selector mechanism with selector
lever cable must be renewed.
– Carefully
push locking mechanisms of selector lever cable to‐
gether -arrows- and remove selector lever cable upwards out
of cable support bracket.
– Shift selector lever on selector mechanism to position “N”. On‐
ly in this position the selector lever cable can be released.
– Remove propshaft on all-wheel drive model ⇒ Rep. gr. 39 ;
Propshaft; Removing and installing propshaft .
– Install centre tunnel heat shield below selector mechanism ⇒
General body repairs, exterior; Rep. gr. 66 ; Mouldings/trims/
extensions; Removing and installing floor heat shield .
– Remove plug and securing clip -arrow-.
Always renew securing clip.
– Fit
a large screwdriver in grooves of locking element and turn
it 90° in direction of arrow.
– Pull cable out of selector mechanism and remove.
Installing
Note
♦
Do not bend or kink gear selector cable.
♦
Do not grease selector lever cable.
♦
Ensure that selector lever cable moves freely after installing.
• Selector lever on selector mechanism must be set to position
“N”. Only in this position the selector lever cable can be en‐
gaged.
3. Selector mechanism 81
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Insert selector lever cable into selector mechanism until it is
visible in locking mechanism
-arrow-.
– With
a large screwdriver, turn locking element 90° in direction
of arrow.
– The selector lever cable is properly engaged when the
grooves in the locking element are at right angles to the se‐
lector lever cable.
– Install new securing clip -arrow- and insert plug.
– Install
– Install propshaft on all-wheel drive model ⇒ Rep. gr. 39 ;
– Check and adjust selector lever cable
– Check selector mechanism ⇒ page 83 .
– Install air filter housing.
Diesel engine
– ⇒ Rep. gr. 23 ; Air filter; Removing and installing air filter
Vehicles with petrol engine
– ⇒ Rep. gr. 24 ; Air filter; Removing and installing air filter
Continue installation in reverse order of removal.
82 Rep. gr.34 - Controls, housing
heat shield below selector mechanism ⇒ General body
repairs, exterior; Rep. gr. 66 ; Mouldings/trims/extensions;
Removing and installing floor heat shield .
Propshaft; Removing and installing propshaft .
housing
housing
⇒ page 83 .
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
3.7 Checking selector mechanism
The starter must not operate in the selector lever positions “R”,
“D” and “S” and in the Tiptronic position.
On right-hand drive vehicles, the starter must operate in selector
lever positions “P” and “N” only when the button in the selector
lever handle is not pressed.
Above 5 km/h:
When the selector lever is shifted to “N”, the selector lever lock
solenoid must not lock the selector lever. Selector lever can be
shifted back into a driving range.
Below 5 km/h:
When the selector lever is shifted to “N”, the selector lever lock
solenoid
Selector lever cannot be shifted out of “N” position until brake
pedal is depressed.
Selector lever in “P” position and ignition switched on
• Brake pedal not depressed:
Selector lever is locked and cannot be shifted out of “P” position
when the button is pressed. Solenoid for selector lever lock blocks
selector lever.
• Brake pedal is depressed:
Solenoid for selector lever lock releases selector lever. It is pos‐
sible to shift into a driving gear. Slowly shift selector lever from
“P” through to “S”, checking whether selector lever position in
dash panel insert corresponds to selector lever position.
Selector lever in “N” position and ignition switched on
• Brake pedal not depressed:
Selector lever is locked and cannot be shifted out of “N” position
with the push button pressed. Solenoid for selector lever lock
blocks selector lever.
• Brake pedal is depressed:
Solenoid for selector lever lock releases selector lever. It is pos‐
sible to shift into a driving gear.
Selector lever in position “Tiptronic”
• Shift selector lever into Tiptronic gate.
The illumination of the “D” symbol in the selector mechanism cov‐
er must go out. “+” and “-” symbols must light up.
When the selector lever is shifted into the Tiptronic gate, the se‐
lector lever position display in the dash panel insert must change
from “P R N D S” to “6 5 4 3 2 1”.
Ignition and light switched on
The respective symbol in the shift mechanism cover lights up.
Selector lever position indicator
Simultaneous illumination of all selector lever position display
segments indicates gearbox emergency running mode.
3.8 Checking and adjusting selector lever
Special tools and workshop equipment required
must lock the selector lever only after approx. 1 second.
cable
3. Selector mechanism 83
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
♦ Torque wrench - V.A.G 1331-
Brief description
Selector lever cable must be removed from gearbox so that its
ease
of movement can be checked. Put removed end down so it
does not rub against anything.
Then the selector lever must be moved and after that, the Bowden
cable must be reattached to the gearbox.
Then the selector lever cable must be adjusted.
Do not grease connections of cable!
Always adjust selector lever cable if the following applies:
♦ The selector lever cable has been removed from the gearbox.
♦ The engine and/or gearbox has been removed and installed.
♦ Parts of the assembly mounting have been removed and in‐
stalled.
♦ The cable itself or the selector mechanism has been removed
and installed.
♦ The position of the engine and gearbox is shifted, for example
to install it free of tension.
Check
– Switch selector lever to »P« position.
– Remove air filter housing.
Diesel engine
– ⇒ Rep. gr. 23 ; Air filter; Removing and installing air filter
Tiguan with petrol engine
– ⇒ Rep. gr. 24 ; Air filter; Removing and installing air filter
84 Rep. gr.34 - Controls, housing
housing
housing
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
Continuation for all:
– Pry
selector lever cable -arrow- off lever using an open-ended
spanner.
Caution
Locks on selector lever cable break off very easily. If a locking
lug has broken off, complete selector mechanism with selector
lever cable must be renewed.
– Carefully
push locking mechanisms of selector lever cable to‐
gether -arrows- and remove selector lever cable upwards out
of cable support bracket.
– Do not bend or kink cable.
– Shift selector lever several times from position »P« to »S« and
back to »P«.
• Selector lever must move easily.
– Reinstall cable.
– Then adjust selector lever cable.
Adjusting
– Move selector lever in vehicle to “P” position.
– Selector shaft on gearbox is also in position “P”. To check,
push lever opposite to driving direction to rear stop.
Note
Raise vehicle, to be sure that the gearbox is in “P” (parking lock
engaged). It should not be possible to turn both front wheels to‐
gether in the same direction.
– Loosen bolt -2- of the Bowden cable -1-.
– Gently push knob of selector lever forwards and backwards
but under no circumstances must you shift out of “P”.
– Tighten bolt -2- to 15 Nm.
This completes the adjustment.
– Install air filter housing.
Diesel engine
– ⇒ Rep. gr. 23 ; Air filter; Removing and installing air filter
housing
Tiguan with petrol engine
– ⇒ Rep. gr. 24 ; Air filter; Removing and installing air filter
housing
3.9 Renewing oil seal for selector shaft
Brief description
The seal can be renewed only with the gearbox removed.
Special tools and workshop equipment required
3. Selector mechanism 85
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
♦ Tube - VW 423-
♦ Extractor hook - T20143-
♦ Not illustrated: Torque wrench - V.A.G 1331– Remove gearbox ⇒ page 89 .
– Remove selector lever cable from gearbox ⇒ page 71 .
– Unscrew securing nut -arrow- and carefully pull gearbox se‐
lector lever -A- off selector shaft.
– Pry seal out -in direction of arrow-.
– Lightly oil outer circumference of new oil seal.
86 Rep. gr.34 - Controls, housing
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Fill
space between sealing lip and dust lip -arrow- with sealing
grease - G 052 128 A1- .
– Drive new seal in onto limit stop. Do not cant oil seal in the
process.
• Closed side of oil seal -arrow-
points towards tube - VW 423- .
– Install gearbox selector lever -A-, and tighten new nut
-arrow-. Specified torque: ⇒ Item 21 (page 153) .
Gearbox selector lever fits on splines in only one position
– Install gearbox ⇒ page 146 .
– Install
and adjust selector lever cable on gearbox
⇒ page 83 .
3. Selector mechanism 87
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
4 Removing and installing gearbox
⇒ “4.1 Specified torques for gearbox”, page 88
⇒ “4.2 Removing gearbox”, page 89
⇒ “4.3 Installing gearbox”, page 146
⇒ “2.3 Detaching bevel box from gearbox - gearbox removed”,
page 57
4.1 Specified torques for gearbox
⇒ “4.1.1 Gearbox carrier to engine and bevel box”, page 88
Item Bolt Nm
1, 2, 3 M12x55 80
• With insert tool
T10179 or
T10509:
»65 Nm«
4 M12x65 80
5, 6, 7 M10x50 40
8 M12×70 80
A Dowel sleeves for centring
Component Nm
Assembly mountings to gearbox (renew bolts after
60 Nm + turn 90° further
each removal)
Earth strap to assembly mounting 25
Heat shield for right drive shaft to bevel box 20
Propshaft to bevel box ⇒ Rep. gr. 39 ; Propshaft; Assembly overview - prop‐
shaft
Bevel box to gearbox
♦ Renew bolts after re‐
moving.
4.1.1 Gearbox
Installation location and tightening sequence:
Diesel engine
Item
A M10 x 21
B M10 x 45
Sequence Bolts Specified torque
1) -A- and -B- Screw in to contact by hand
2) Tighten -A- 40 Nm
3) Tighten -B- 40 Nm
Petrol engine
88 Rep. gr.34 - Controls, housing
Bolt
carrier to engine and bevel box
40 Nm + 90° further
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
Installation location and tightening sequence:
Item Bolt
1 M10 x 21
2 M10 x 45
Sequence Bolts Specified torque
1) -1- and -2- Screw in to contact by hand
2) Tighten -2- 40 Nm
3) Tighten -1- 40 Nm
Heat shield for propshaft
♦ Bolt -A-: 20 Nm
♦ Bolt -B-: 40 Nm
7-speed dual clutch gearbox 0DL - Edition 04.2017
4.2 Removing gearbox
⇒ “4.2.1 Removing gearbox, Passat 2015 ►, Passat Estate 2015
►, Arteon 2018 ►, vehicles with 2.0 l - 176 kW TDI and bi-turbo‐
charger”, page 89
⇒ “4.2.2 Removing gearbox, Passat 2015 ►, Passat Estate 2015
►, vehicles with petrol engine”, page 100
⇒ “4.2.3 Removing gearbox, Tiguan 2016 ► vehicles with 2.0 l 105 kW, 110 kW, 130 kW, 140 kW diesel engine, all-wheel drive”,
page 111
⇒ “4.2.4 Removing gearbox, Tiguan 2016 ►, vehicles with petrol
engine, all-wheel drive”, page 120
⇒ “4.2.5 Removing gearbox, Tiguan 2016 ►, vehicles with diesel
engine, front-wheel drive”, page 130
⇒ “4.2.6 Removing gearbox, Tiguan 2016 ►, vehicles with 2.0 l 176 kW TDI”, page 137
4.2.1 Removing gearbox, Passat 2015 ►,
Brief description
The gearbox is removed downwards together with the bevel box.
»From above«
The battery, air filter and starter are removed. The coolant hoses
must be clamped off. Support engine and gearbox before left
subframe mounting is unbolted.
»From below«
The -subframe-
-both suspension links-.
Passat Estate 2015 ►, Arteon 2018 ►,
vehicles with 2.0 l - 176 kW TDI and biturbocharger
is removed together with -pendulum support- and
4. Removing and installing gearbox 89
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
Both drive shafts are disconnected from gearbox and left installed
in wheel bearing housings. They are only swivelled to one side
and left on vehicle.
Special tools and workshop
equipment required
♦ Support - 10-222A♦ Shackle - 10 - 222 A /12♦ Support - 10 - 222 A /31♦ Engine support, basic set - T40091♦ Engine support supplement set - T40093♦ Gearbox support - 3282-
90 Rep. gr.34 - Controls, housing
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♦ Engine and gearbox
jack - V.A.G 1383 Aor engine and gear‐
box jack - VAS 6931-
♦ Adjustment plate -
3282/42 A-
♦ Hose clamps to 25
mm - 3094-
♦ Tensioning strap -
T10038-
♦ Set of plugs for en‐
gine - VAS 6122-
♦ Insert tool, 18 mm -
T10179-
♦ Insert tool, 18 mm -
T10509-
Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
♦ Socket, multi-point bit
XZN 14 - T10061-
4. Removing and installing gearbox 91
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
♦ Counter-hold tool -
T10172A-
♦ Support bridge -
T10323-
♦ Adapter -
T40093/3-6- : qty. 2
(check and modify as
necessary
⇒ page 92 )
♦ or adapter -
T40093/3-6A- : qty. 2
Check adapters T40093/3-6- and modify
as necessary
– If necessary, cut off
the marked area.
– Round off front
edges.
– Protect adapter
against corrosion.
– Then, mark adapters
- T40093/3-6- as T40093/3-6A- .
At a later point, support
bracket - 10-222 A- will
be
fitted onto longitudinal
members with adapters T40093/3-6A- .
92 Rep. gr.34 - Controls, housing
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
• To prevent damage
to the longitudinal
members, wrap the
front section of the
adapters T40093/3-6A- with
textile-reinforced ad‐
hesive tape ⇒ Elec‐
tronic
parts catalogue
(ETKA chemical sub‐
stances) .
Removing:
– Raise vehicle. All 4
supports of lifting
platform must be at
same height.
Note
So that the propshaft can
be turned later in order to
loosen it:
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Move selector lever
to »N« position.
– Remove complete air
filter housing ⇒ Rep.
gr. 23 ; Air filter; Re‐
moving and installing
air filter housing .
Battery in engine com‐
partment
– Remove battery and
battery tray ⇒ Electri‐
cal system; Rep. gr.
27 ; Battery; Remov‐
ing and installing bat‐
tery tray .
Battery in luggage com‐
partment
– Remove air filter housing bracket ⇒ Rep. gr. 23 ; Air filter;
Removing and installing air filter housing .
The bracket is similar to the one shown.
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
Removing and installing starter .
4. Removing and installing gearbox 93
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Pry selector lever cable off selector shaft lever -arrow- using
an open-ended spanner.
Caution
Locks on selector lever cable break off very easily. If a locking
lug has broken off, complete selector mechanism with selector
lever cable must be renewed.
– Carefully
push locking mechanisms of selector lever cable to‐
gether -arrows- and remove selector lever cable upwards out
of cable support bracket.
– Do not bend or kink cable.
– Clamp
off coolant hoses using hose clamps to 40 mm - 3093-
or hose clamps to 25 mm - 3094- and remove.
– Seal connecting necks of gear oil cooler using suitable plugs
from engine bung set - VAS 6122- .
– Disconnect connector -1- for mechatronic unit for dual clutch
gearbox - J743- . To do this, turn rotary locking mechanism
anti-clockwise -arrow-
.
– Remove charge air pipe ⇒ Rep. gr. 21 ; Charge air system;
Assembly overview - charge air system .
– Unscrew upper engine/gearbox connecting bolts using insert
tool 18 mm - T10179- or insert tool 18 mm - T10509- .
94 Rep. gr.34 - Controls, housing
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
A bolt is located in the starter motor hole -arrow-.
This bolt can be
removed using socket - T10061- .
– If there are hose and cable connections in area of engine sup‐
port eyes for support bracket - 10-222A- , remove these now.
– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system; Removing and installing wiper arms .
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Plenum chamber cover; Removing and
installing plenum chamber cover .
– If there are hose and cable connections in area of engine sup‐
port eyes for support bracket - 10-222A- , remove these now.
– Install support bracket - 10-222 A- as follows:
Required material:
♦ Adapter - 10 - 222 A /31-1♦ Adapter - 10 - 222 A /31-2♦ Connector - T40091/3♦ Square tube - T40091/1♦ Spindle from engine support supplement set - T40093 /3♦ Adapter - T40093/3-6- : qty. 2 (check and modify as necessary
⇒ page 92 )
♦ or adapter - T40093/3-6A- : qty. 2
– Detach cover caps on bolted connections for suspension
struts (front).
– Fit
adapter - 10 - 222 A /31-1- and adapter - 10 - 222 A /31-2-
-A- onto suspension strut mountings.
The webs -arrow- must face towards front end.
– Slide
– Bolt support bracket - 10-222 A- to adapter - 10 - 222 A /31-1-
-A- = adapter - T40093/3-6A- (⇒ next figure)
connector - T40091/3- onto support bracket - 10-222 A- .
and to adapter - 10 - 222 A /31-2- .
4. Removing and installing gearbox 95
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Arteon 2018 ➤ , Passat 2015 ➤ , Passat Variant 2015 ➤ , Tiguan 2016 ➤ , ...
7-speed dual clutch gearbox 0DL - Edition 04.2017
– Remove
fuel filter and lay to side. Do not open pipe/hose sys‐
tem ⇒ Rep. gr. 20 ; Fuel filter; Assembly overview - fuel filter .
– Place adapters - T40093/3-6A- onto both longitudinal mem‐
bers (illustration shows right longitudinal member).
– If necessary, carefully unclip any pipes for air conditioning
system in front area. Do not disconnect pipe/hose system ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - refrigerant circuit .
– Position adapter - T40093/3-6A- on left longitudinal member
directly behind filler pipe for washer fluid reservoir.
• Each of the adapters - T40093/3-6A- locks with pin -A-
behind
the web of the longitudinal member -arrow-.
– Screw on spindle from engine support supplement set -
T40093 /3- , connect it via square tube - T40091/1- to engine
support bracket - 10-222 A- and fasten connection (⇒ previous
fig.).
• The square tube - T40091/1- must be flush with the connecting
piece - T40091/3- and the engine support supplement set T40093 /3- (⇒ previous figure).
– Then attach spindles to engine support eyes.
– Take up weight of engine/gearbox assembly and support
bracket on spindles .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
– Remove lower part of front left wheel housing liner ⇒ General
– Remove electrical wiring and retainers from sump at front
– Raise wiring in area of sump and secure it.
96 Rep. gr.34 - Controls, housing
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; As‐
sembly overview - front wheel housing liner .
-arrows-.
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