Volkswagen Jetta 2005 User Manual
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Service
Workshop Manual
Golf Variant 2007 ➤
Golf Variant 2010 ➤
Jetta 2005 ➤
Jetta 2011 ➤
7-speed dual clutch gearbox 0AM
Edition 07.2010
Service Department. Technical Information
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Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Re pa ir G ro up
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - front differential
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2010 Volkswagen AG, Wolfsburg MEX5R008520
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-speed dual clutch gearbox 0AM - Edition 07.2010
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Code, engine allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.2 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.3 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.4 Working with vehicle diagnostic testers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1 Removing and installing the dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Removing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Adjusting position of engagement bearings “K 1 and K 2” . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3 Installing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1 Renewing gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.1 Overview - selector mechanism in vehicles up to 02.2009 . . . . . . . . . . . . . . . . . . . . . . . . 33
2.2 Removing and installing selector lever cable - vehicles up to 02.2009 . . . . . . . . . . . . . . . . 34
2.3 Overview of selector mechanism - vehicles from 03.2009 onwards . . . . . . . . . . . . . . . . . . 41
2.4 Removing and installing selector mechanism with selector lever and selector lever cable -
vehicles from 03.2009 onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.5 Checking selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.6 Adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.7 Emergency release of selector lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.8 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.9 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3 Mechatronic unit for dual clutch gearbox J743 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.1 Safety note on mechatronic unit for dual clutch gearbox J743 . . . . . . . . . . . . . . . . . . . . . . 50
3.2 Overview - mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.3 Removing mechatronic unit for dual clutch gearbox J743 with gearbox installed . . . . . . . . 52
3.4 Moving mechatronic unit for dual clutch gearbox J743 into “removal position” by hand . . 62
3.5 Installing mechatronic unit for dual clutch gearbox J743 . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.6 View of selector forks with mechatronic unit removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.1 Information about gearboxes with different output shafts . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.2 Removing gearbox, vehicles with 1.4 l/90 kW TFSI engine and 1.4 l/118 kW TSI engine
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.3 Removing gearbox, vehicles with 1.6 l/75 kW MPI engine . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.4 Removing gearbox - vehicles with 1.9 l/77 kW TDI PD engine . . . . . . . . . . . . . . . . . . . . . . 90
4.5 Removing gearbox - vehicles with 1.6 l/77 kW TDI CR engine . . . . . . . . . . . . . . . . . . . . . . 97
4.6 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.7 Torque settings “Gearbox to engine” and notes on assembly mounting . . . . . . . . . . . . . . 107
5 Transporting gearbox and securing to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1 Currently, no repairs can be made to gears and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
1 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Contents i
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-speed dual clutch gearbox 0AM - Edition 07.2010
1.1 Renewing oil seal for right stub shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
1.2 Renewing oil seal for left stub shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.3 Renewing seal for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
1.4 Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
ii Contents
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
00 – Technical data
1 Gearbox identification
KHN - Gearbox code letters
⇒ page 2
01.06.06 - Production date:
1 June 2006
14 - Factory code
14 15 - Time
0026 - Serial number
7-speed dual clutch gearbox 0AM - Edition 07.2010
1. Gearbox identification 1
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-speed dual clutch gearbox 0AM - Edition 07.2010
2 Code, engine allocation
Allocation: gearbox codes for petrol engines
KHN, LKG, LKM KUT, LPL LSU
1.4 l/90 kW TSFI 1.4 l/118 kW TSI 1.6 l/75 kW MPI
Allocation: gearbox codes for diesel engines
KHM, LKL, LKF LQN, LST
1.9 l/77 kW TDI PD 1.6 l/77 kW TDI CR
2 Rep. Gr.00 - Technical data
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.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-speed dual clutch gearbox 0AM - Edition 07.2010
3 Capacities
Dual clutch gearbox 0AM Mechatronic unit for dual clutch
1.7 l gear oil -G 052 171- 1 l central hydraulic oil and power
Further information in the part number designates the container
size.
gearbox -J743-
steering oil -G 004 000-
3. Capacities 3
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.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-speed dual clutch gearbox 0AM - Edition 07.2010
4 General repair notes
4.1 Tools
Uncertainty often occurs with smaller bolts having low tightening
forces. Torque wrench 2...10 Nm -V.A.G 1783- can be used with
these bolts.
4.2 Gearbox
The gearbox has a hole in the housing.
4 Rep. Gr.00 - Technical data
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
– Make sure no small parts drop into this hole during installation
work.
7-speed dual clutch gearbox 0AM - Edition 07.2010
– Cover the hole with a cloth before installation work.
Make sure that no dirt can enter an “open” gearbox.
♦ If gearbox covers have been unbolted or gearbox has no fluid,
do not run engine. Do not tow vehicle.
♦ First thoroughly clean connecting points and surrounding
areas and then loosen bolts.
♦ During installation, ensure that the dowel sleeves between the
engine and gearbox are correctly located.
♦ Place removed parts on a clean surface. Cover parts to pre‐
vent soiling. Use plastic sheeting and paper. Use lint-free
cloths only!
♦ Install only clean parts; do not remove Genuine parts from
packaging until immediately before installing.
♦ If repair work cannot be performed immediately, cover opened
parts carefully.
4. General repair notes 5
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-speed dual clutch gearbox 0AM - Edition 07.2010
In some vehicles, a cover is fitted over the engaging levers.
The cover prevents dirt getting in.
Torque setting: 8 Nm
4.3 Oil
The “0AM” gearbox has two oil circuits. One oil fill is for gears,
shafts and differential. A 2nd oil fill is for mechatronic unit for dual
clutch gearbox -J743- .
Both oils are Genuine parts ⇒ page 3 .
Do not mix “additives” in oil.
Oil which has been drained out cannot be added again.
Caution
Use caution when handling oil. Dispose of used oil properly.
One drop of oil will contaminate 600 litres of water.
4.4 Working with vehicle diagnostic testers
• Only work with vehicle diagnostic testers from Volkswagen.
♦ Vehicle diagnosis and service information system -VAS 5052
A-
♦ Vehicle diagnosis, testing and information system -VAS
5051B-
♦ Vehicle diagnostic tester -VAS 5053Various functions are available in the operating modes guided
functions and guided fault finding . The 3 most important
functions are:
♦ Adapting installation information
♦ Reading measured values for mandatory reporting
♦ Initiating basic adjustment
4.4.1 Adapting installation information
The mechatronic unit detects other control units in the vehicle by
means of signals on the data bus. Pressing the Adapt instal-
lation information lock button instructs the mechatronic unit
to forget all communication partners.
6 Rep. Gr.00 - Technical data
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
All “active partners” are detected once again the next time the
ignition system is switched on.
You cannot “generate” any faults using this function. Please al‐
ways perform the Adapt installation information function
after the following activities:
♦ After a selector lever has been installed.
♦ After another control unit has been installed, e.g. engine, ABS
or gateway.
♦ After work on the steering wheel paddle.
4.4.2 Reading measured values for mandato‐
You must read these measured values before contacting your
ry reporting
Technical Service Center or your importer.
Save the measured values in the diagnosis log so that all neces‐
sary gearbox data will be available for fault analysis.
4.4.3 Initiating basic adjustment
This teaches important settings into the mechatronic unit. Even
important adjustments are taught in again, or reset to program‐
med points. These include, for example, the synchronisation
points and “reference points” for the engaging lever and gear ac‐
tuator.
– Press the button DSG Mechatronic -J743- performing
7-speed dual clutch gearbox 0AM - Edition 07.2010
basic measurement only:
♦ if you are prompted to do so in “guided fault finding”
♦ after you have processed a fault entry
♦ after you have installed another gearbox
♦ after you have installed a clutch
♦ or after you have installed a mechatronic unit
4. General repair notes 7
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.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-speed dual clutch gearbox 0AM - Edition 07.2010
30 – Clutch
1 Removing and installing the dual
clutch
Brief description
The clutch is installed “upwards” with the gearbox removed. The
mechatronic unit remains on the gearbox.
If one new clutch is installed, the positions of the engagement
bearings for “K 1” and “K 2” must be found and set. Then the clutch
is pressed onto the input shaft.
When installing a clutch, “most” mechanics push the clutch onto
the input shaft up to the stop. This is not the optimum position for
the clutch!
For this reason, pull the clutch slightly “upwards” against the re‐
taining ring after it has been installed.
After the gearbox has been installed, you must initiate a ba-
sic adjustment using the ⇒ Vehicle diagnosis, testing and
information system VAS 5051 ⇒ page 7 .
Note
The clutch is self-adjusting. Shocks can have an effect on this
adjusting device. Therefore, please do not drop the clutch. Do not
left the clutch drop into the gearbox either when installing the
clutch. Even if the mechatronic unit has been removed, “pulling
out” the assembly lever -T10407- under the engaging levers can
have a negative effect on the adjusting device.
Transporting gearbox and securing to assembly stand
⇒ page 111 .
Remove dual clutch ⇒ page 8 .
Adjust the position of the engagement bearings “K 1 and K 2”
⇒ page 12 .
Install dual clutch ⇒ page 22 .
1.1 Removing dual clutch
Special tools and workshop equipment required
♦ Hook -3438-
8 Rep. Gr.30 - Clutch
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♦ Support device -T10323-
♦ Assembly tool -T10356-
♦ Puller -T10373-
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-speed dual clutch gearbox 0AM - Edition 07.2010
♦ Thrust piece -T10376-
– Remove gearbox ⇒ page 73 .
1. Removing and installing the dual clutch 9
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.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-speed dual clutch gearbox 0AM - Edition 07.2010
– Pull off both breather caps -arrows- and close using suitable
plugs to achieve an oil-tight seal.
Turn gearbox with clutch upwards.
For information about how to transport the gearbox securely and
attach it to the assembly stand ⇒ page 111 .
– Remove retaining ring of hub -arrow-.
– Remove hub with hook -3438- and a screwdriver.
10 Rep. Gr.30 - Clutch
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-speed dual clutch gearbox 0AM - Edition 07.2010
– Remove retaining ring of clutch -arrow-.
Note
♦
It is possible that the retaining ring is seated very tightly. The
cause may be that the clutch is pressing so hard against the
retaining ring that the ring is stuck.
♦
If you cannot get the ring out of the groove, press the clutch
down slightly. Never strike the clutch or shaft with a hammer!
Set up the tools that are shown in this illustration.
♦
Support bracket -T10323- fits on all 0AM gearboxes.
♦
Make sure that you place support bracket -T10323- in parallel
to the gearbox flange.
♦
Secure engine support with bolts -A-, as required with nuts.
♦
Always renew retaining ring.
Clutch should only be pressed down slightly. Often, it is sufficient
to rotate spindle against thrust piece -T10376- without pressing.
This will “release” retaining ring.
– Pull off clutch.
– Remove clutch together with puller -T10373- .
1. Removing and installing the dual clutch 11
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-speed dual clutch gearbox 0AM - Edition 07.2010
– Remove small engagement bearing.
– Remove large engaging lever.
– Remove bolts and remove small engaging lever.
– Remove retainer for engaging lever.
Before installing clutch, please refer to ⇒ page 12 to see wheth‐
er “clutch needs adjusting during assembly or not.”
Adjusting ⇒ page 12 .
Install dual clutch ⇒ page 22 .
1.2 Adjusting position of engagement bear‐
ings “K 1 and K 2”
Special tools and workshop equipment required
♦ Gauge block -T10374-
12 Rep. Gr.30 - Clutch
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-speed dual clutch gearbox 0AM - Edition 07.2010
♦ Ruler -T40100-
♦ Digital depth gauge e.g. -VAS 6594-
♦ Adhesive -AMV 195 KD1 01-
♦ Micrometer caliper
Position of engagement bearings must be set after clutch and its
actuators have been renewed.
♦ Retainer also belongs to actuator.
There is no need to adjust anything if all the named parts have
only been removed and reinstalled.
Conditions:
• Only use tools in perfect condition.
• Contact surface of “gearbox on engine” must be free from “ir‐
regularities”. This guarantees straight edge makes good con‐
tact.
• Mechatronic unit is installed.
Perform the following steps:
Position of engagement bearings is comparable with clutch play
of a manual gearbox. In this 0AM dual clutch gearbox, there are
tolerances in engagement system of gearbox and in gearbox it‐
self. There are also tolerances within the dual clutch. These
tolerances must be considered separately when adjusting.
In the following procedure, you are first shown how to measure
all necessary dimensions “on gearbox”, in order to determine
what is the appropriate shim. Tolerances on gearbox and toler‐
ances in clutch determine thickness of shim.
First find a dimension “B”. This dimensions is required for both
clutches “K 1” and “K 2”.
Then find a dimension “A” for each clutch. The following 2 illus‐
trations show where to measure these dimensions.
1. Removing and installing the dual clutch 13
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-speed dual clutch gearbox 0AM - Edition 07.2010
“K 1”
“K 2”
Note
Perform the following steps “in sequence” and precisely.
Adjusting:
– Install parts of clutch as far as large engaging lever
⇒ page 22 .
Do not install small engagement bearing, do not insert any shim.
14 Rep. Gr.30 - Clutch
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-speed dual clutch gearbox 0AM - Edition 07.2010
– Install retaining ring of outer input shaft -arrow-.
– Place a ruler -T40100- on its side on flange of clutch housing.
It should lie sideways on shaft end.
Note
Ruler -T40100- should remain in this position during subsequent
measurements. Do not turn over, do not remove.
– Place digital depth gauge onto outer input shaft.
– “Zero” depth gauge.
– Measure distance from retaining ring.
– Note down result and call it “B”.
Example: “B” = 2.91 millimetres
1. Removing and installing the dual clutch 15
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-speed dual clutch gearbox 0AM - Edition 07.2010
– Measure dimension “B” again on opposite side.
Note
Do not measure on ring joint. This could force ring away at that
point and falsify measuring result.
– Remove retaining ring again.
This ring is not allowed to be installed again!
– Calculate average of both measuring results.
Example:
Dimension “B” = B1+B22 = 2,91+3,02 = 2.96
This dimension “B” is needed in the following calculations.
In the following sample calculations, “B” should be 2.96 mm. The
dimension given for “B” is and example. The value for “B” may be
different in another gearbox.
There are 2 clutches, therefore there are 2 setting procedures to
follow.
Each measurement requires different preparatory measures, as
well as a few calculations. Please comply with the following work‐
ing procedures.
Start by calculating shim for clutch “K 1”.
Do not insert any shim!
– Place gauge block -T10374- on “large” engagement bearing.
– Press once onto gauge block -T10374- whilst turning.
In this way, it is possible to observe how the engagement bearing
turns. This means gauge block -T10374- also “sits” correctly on
bearing.
– Place digital depth gauge “at top” onto outer input shaft.
Ruler -T40100- is already “on its side” on gearbox flange
⇒ page 15 .
16 Rep. Gr.30 - Clutch
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-speed dual clutch gearbox 0AM - Edition 07.2010
– Measure distance from “shaft end” to gauge block -T10374- .
1. Removing and installing the dual clutch 17
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-speed dual clutch gearbox 0AM - Edition 07.2010
– To make sure this measurement is as accurate as possible,
position digital depth gauge twice at opposite sides.
This allows the value to be found even more accurately, because
the inaccuracy caused by “tilting” on the engagement bearing is
minimised.
– Calculate average of both measurements onto gauge block -
T10374- .
– Note down this value and call it “A1”.
Example:
Dimension “A1” = 2,61+2,812 = 2.71
Example: “A1” = 2.71 millimetres
Next calculation:
“A1” minus “B” plus height of gauge block -T10374- = Depth of
engagement bearing of clutch 1.
Height of gauge block -T10374- is always the same. It is: 51.81
mm.
Sample calculation:
2.71 mm minus 2.96 mm plus 51.81 mm = 51.56 mm.
You have now calculated value for how deep engagement bear‐
ing is actually seated inside gearbox.
Depth of bearing in each gearbox should be 50.08 millimetres.
Subtract nominal dimension “50.08 millimetres” from this actual
value. This gives result for actual gap of clutch 1.
– Continue the calculation:
Calculated value (in example: 51.56 mm) minus nominal dimen‐
sion = gap of clutch.
Sample calculation:
51.56 mm minus “50.08 millimetres” = gap of clutch 1 = 1.48 mm.
Now tolerances in dual clutch must be introduced into this calcu‐
lation. Procedure for this is very simple:
– Please read off value of clutch tolerance of “new” clutch.
A value between minus 0.40 and plus 0.40 millimetres is provided
with a new clutch.
– Make a note of this value.
Example 1: “- 0.40” is indicated on your clutch.
The previous calculation for “K 1”: “your calculated” gap minus
value of clutch 1 =
1.48 mm minus 0.40 = 1.08 mm.
Example 2: “+ 0.20” is indicated on your clutch.
Then, the last calculation of “K 1” is as follows: 1.48 mm plus 0.20
= 1.68 mm.
– Refer to table to find correct shim and install.
18 Rep. Gr.30 - Clutch
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-speed dual clutch gearbox 0AM - Edition 07.2010
Calculated shim thickness Shim to be installed (in milli‐
metres)
from to
0.31 0.90 0.8
0.91 1.10 1.0
1.11 1.30 1.2
1.31 1.50 1.4
1.51 1.70 1.6
1.71 1.90 1.8
1.91 2.10 2.0
2.11 2.30 2.2
2.31 2.50 2.4
2.51 2.70 2.6
2.71 3.30 2.8
– From the supplied shims, select the one that is required.
Later on, only insert this 1 shim. Not 2 shims.
With this, you have found “correct” shim for “K 1”. Please install
this shim during subsequent clutch installation.
– Continue setting for clutch “K 2”.
Calculate shim for clutch “K 2”.
– Only insert small bearing.
WARNING
Do not insert any shim!
Small engagement bearing only fits in one position due to 4
grooves.
1. Removing and installing the dual clutch 19
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-speed dual clutch gearbox 0AM - Edition 07.2010
– By “turning”, check whether small engagement bearing is in‐
stalled correctly and that grooves are seated correctly.
– Place gauge block -T10374- on small bearing “with large
opening upwards”.
– Place digital depth gauge “at top” onto outer input shaft.
– “Zero” depth gauge.
– Measure distance from “shaft end” into gauge block -T10374- .
20 Rep. Gr.30 - Clutch
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-speed dual clutch gearbox 0AM - Edition 07.2010
– To make sure this measurement is as accurate as possible,
position digital depth gauge twice at opposite sides.
This allows the value to be found even more accurately, because
the inaccuracy caused by “tilting” on the engagement bearing is
minimised.
– Calculate average of both measurements onto gauge block -
T10374- .
– Note down this value and call it “A2”.
Example:
Dimension “A2” = 2,50+2,542 = 2.52
Example: “A2” = 2.52 millimetres
Next calculation:
“A2” minus “B” plus height of gauge block -T10374- = Depth of
engagement bearing of clutch 2.
Height of gauge block -T10374- is always the same. On inside, it
is: 36.20 mm.
Sample calculation:
2.52 mm minus 2.96 mm plus 36.20 mm = 35.76 mm.
You have now calculated value for how deep engagement bear‐
ing is actually seated inside gearbox.
Depth of bearing in each gearbox should be 34.35 millimetres.
Subtract nominal dimension “34.35 millimetres” from this actual
value. This gives result for actual gap of clutch 2.
– Continue the calculation:
Calculated value (in example: 35.76 mm) minus nominal dimen‐
sion = gap of clutch.
Sample calculation:
35.76 mm minus “34.35 millimetres” = gap of clutch 2 = 1.41mm.
Now tolerances in dual clutch must be introduced into this calcu‐
lation. Procedure for this is very simple:
– Please read off value of clutch tolerance of “new” clutch.
A value between minus 0.40 and plus 0.40 millimetres is provided
with a new clutch.
– Make a note of this value.
Example 1: “- 0.40” is indicated on your clutch.
The previous calculation for “K 2”: “your calculated” gap minus
value of clutch 2 =
1.41 mm minus 0.40 = 1.01 mm.
Example 2: “+ 0.20” is indicated on your clutch.
Then, the last calculation of “K 2” is as follows: 1.41 mm plus 0.20
= 1.61 mm.
– Refer to table to find correct shim.
1. Removing and installing the dual clutch 21
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-speed dual clutch gearbox 0AM - Edition 07.2010
Calculated shim thickness Shim to be installed (in milli‐
from to
0.31 0.90 0.8
0.91 1.10 1.0
1.11 1.30 1.2
1.31 1.50 1.4
1.51 1.70 1.6
1.71 1.90 1.8
1.91 2.10 2.0
2.11 2.30 2.2
2.31 2.50 2.4
2.51 2.70 2.6
2.71 3.30 2.8
– From the supplied shims, select the one that is required.
WARNING
Later on, only insert this 1 shim. Not 2 shims.
With this, you also have found “correct” shim for “K 2”. Please
metres)
install this shim during subsequent clutch installation. This shim
should be under small engagement bearing.
1.3 Installing dual clutch
Special tools and workshop equipment required
♦ Support device -T10323-
22 Rep. Gr.30 - Clutch
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
♦ Assembly tool -T10356-
♦ Puller -T10373-
♦ Thrust piece -T10376-
♦ Adhesive -AMV 195 KD1 01-
Perform the following steps:
Caution
7-speed dual clutch gearbox 0AM - Edition 07.2010
Do not oil or grease anything!
Before clutch is installed, position of engagement bearings “K 1
and K 2” must be set ⇒ page 12 .
1. Removing and installing the dual clutch 23
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-speed dual clutch gearbox 0AM - Edition 07.2010
– Insert plastic retainer of engaging lever and check for correct
seating.
– Install small engaging lever with clip.
Sleeve with its retaining plate fits only in one position.
Only a few, “older gearboxes” do not have a clip.
“New” clutches always have one clip.
– Check engaging lever is properly seated.
– Screw on engaging lever with 2 new bolts.
Torque setting: 8 Nm + 90°
Note
Mounting for engaging lever and entire mechanism of engage‐
ment bearing must be dry and free from oil or grease. If neces‐
sary, clean these components with a cloth.
– Insert 2nd, “larger” engaging lever.
This “larger” lever is for clutch “K 1”.
– Check both engaging levers are seated correctly.
Caution
Before continuing with assembly, check whether clutch needs
to be adjusted.
Do not continue with the assembly before the clutch has been
adjusted!
Adjust positions of engagement bearings ⇒ page 12 .
24 Rep. Gr.30 - Clutch
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-speed dual clutch gearbox 0AM - Edition 07.2010
– Insert small engagement bearing with measured shim.
Shim should be under small engagement bearing. Therefore, in‐
sert shim first.
Small engagement bearing only fits in one position due to 4
grooves.
If clutch has been replaced, shim should also be under bearing.
– By “turning” bearing, check whether it is installed correctly and
that grooves are seated correctly.
– Secure shim using 3 drops of glue -AMV 195 KD1 01- .
This prevents shim from slipping out of its seat when clutch is
inserted.
Large shim is for clutch “K 1”, small one for clutch “K 2”.
– Turn back spindle of puller -T10373- .
1. Removing and installing the dual clutch 25
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-speed dual clutch gearbox 0AM - Edition 07.2010
– Insert clutch.
– Use puller -T10373- to insert clutch into gearbox.
– Turn spindle “back” first.
Note
The clutch is self-adjusting. Shocks can have an effect on this
adjusting device. Therefore, please do not drop the clutch. Do not
left the clutch drop into the gearbox either when installing the
clutch.
– Press clutch on onto stop.
Support bracket -T10323- fits on all 0AM gearboxes.
– Make sure that you place support bracket -T10323- in parallel
to the gearbox flange.
Secure engine support with bolts -A-, as required with nuts.
– Push clutch down via spindle.
Note
Place a hand on clutch whilst pressing on. You will be able to feel
a slight rattling. Rattling means the clutch is being pressed onto
its press seat. In the same way, you can also “feel” the stop when
the clutch has reached its seat.
Installation position of retaining ring: Joint of retaining ring is “nar‐
rower at top”.
If you can insert retaining ring -arrow-, clutch is correctly pressed
on to stop.
– Insert new retaining ring -arrow-.
26 Rep. Gr.30 - Clutch
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