Volkswagen Golf Variant 2007 Operating instructions

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Repair Manual
Golf Variant 2007 ➤
Golf Variant 2010 ➤
Jetta 2005 ➤
Jetta 2011 ➤
7-Speed Dual Clutch Transmission 0AM
Edition 09.2015
Service
Service Department. Technical Information
ProCarManuals.com

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List of Workshop Manual Repair Groups
Repair Group
00 - General, Technical Data
30 - Clutch
34 - Controls, Housing
35 - Gears, Shafts
39 - Final Drive, 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.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2016 Volkswagen AG, Wolfsburg D4B8035092C
ProCarManuals.com

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Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Transmission Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Overview - Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Engine Codes, Engine Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.1 General Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.2 Safety Precautions when Working on Vehicles with Start/Stop System . . . . . . . . . . . . . . 5
5.3 Safety Precautions during Road Test with Testing Equipment . . . . . . . . . . . . . . . . . . . . . . 6
6 Tow Starting and Towing Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7 General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7.2 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7.3 Working with Vehicle Diagnostic Testers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1 Dual Clutch, Removing and Installing, through Transmission Production Date 05/2011 . . 15
1.1 Overview - Dual Clutch, through Transmission Production Date 05/2011 . . . . . . . . . . . . . . 15
1.2 Dual Clutch, Removing, through Transmission Production Date 05/2011 . . . . . . . . . . . . . . 17
1.3 “K 1” and “K 2” Clutch Engaging Bearing Position, Adjusting, Transmission Production Date
through 05/2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.4 Dual Clutch, Installing, Transmission Production Date through 05/2011 . . . . . . . . . . . . . . 33
2 Dual Clutch, Removing and Installing, from Transmission Production Date 06/2011 . . . . 40
2.1 Overview - Dual Clutch, Transmission Production Date from 06/2011 . . . . . . . . . . . . . . . . 40
2.2 Dual Clutch, Removing, Transmission Production Date from 06/2011 . . . . . . . . . . . . . . . . 42
2.3 “K 1” and “K 2” Clutch Engaging Bearing Position, Adjusting, Transmission Production Date
from 06/2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.4 Dual Clutch, Installing, Transmission Production Date from 06/2011 . . . . . . . . . . . . . . . . 58
3 Clutch-Side Seals, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
34 - Controls, Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1 Transmission Fluid, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2 Selector Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.1 Selector Mechanism Overview, through 02/2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.2 Selector Lever Cable, Removing and Installing, through 02/2009 . . . . . . . . . . . . . . . . . . . . 76
2.3 Selector Mechanism Overview, from 03/2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.4 Selector Mechanism, Removing and Installing, Vehicles from 03/2009 . . . . . . . . . . . . . . . . 85
2.5 Selector Lever Cable, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2.6 Selector Lever Cable, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.7 Selector Lever, Emergency Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.8 Selector Lever Handle, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.9 Button in Handle, Moving into Installation Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2.10 Selector Mechanism, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3 DSG Transmission Mechatronic J743 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.1 DSG Transmission Mechatronic J743 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.2 Overview - Mechatronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.3 DSG Transmission Mechatronic J743 , Removing with Transmission Installed . . . . . . . . 105
3.4 DSG Transmission Mechatronic J743 , Moving into »Removal Position« by Hand . . . . . . 115
3.5 DSG Transmission Mechatronic J743 , Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
3.6 Overview - Shift Forks with Mechatronic Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-Speed Dual Clutch Transmission 0AM - Edition 09.2015
Contents i
ProCarManuals.com

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4 Transmission, Removing and Installing, Jetta from MY 2005, Golf Wagon from MY 2007 and
Golf Wagon from MY 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.1 Transmissions with Different Output Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.2 Transmission, Removing, Vehicles with 1.4L/90 kW TFSI Engine and 1.4L/118 kW TSI
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.3 Transmission, Removing, Vehicles with 1.6L/75 kW MPI Engine . . . . . . . . . . . . . . . . . . . . 135
4.4 Transmission, Removing, Vehicles with 1.9L 77 kW TDI PD Engine . . . . . . . . . . . . . . . . . . 143
4.5 Transmission, Removing, Vehicles with 1.6L/77 kW TDI CR Engine . . . . . . . . . . . . . . . . 150
4.6 Transmission, Installing, Jetta from MY 2005, Golf Wagon from MY 2007, Golf Wagon from
MY 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
4.7 »Transmission to Engine« Tightening Specifications and Subframe Mount Information . . 161
5 Transmission, Removing and Installing, Jetta from MY 2011 . . . . . . . . . . . . . . . . . . . . . . 166
5.1 Transmission, Removing, Jetta 2011 with 1.4L/90 kW TFSI Engine and 1.4L/118 kW TSI
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
5.2 Transmission, Removing, Jetta 2011 with 1.6L/77 kW TDI CR Engine . . . . . . . . . . . . . . . . 175
5.3 Transmission, Installing, Jetta MY 2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
5.4 Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
6 Transmission, Transporting and Securing To Assembly Stand . . . . . . . . . . . . . . . . . . . . . . 191
7 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
35 - Gears, Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
1 Gears and Shafts, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
2 Parking Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2.1 Parking Lock Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2.2 Parking Lock, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
39 - Final Drive, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
1 Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
1.1 Component Location Overview - Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
1.2 Right Stub Shaft Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
1.3 Left Stub Shaft Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
1.4 Right Flange Shaft Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
1.5 Left Flange Shaft Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
3 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-Speed Dual Clutch Transmission 0AM - Edition 09.2015
ii Contents
ProCarManuals.com

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00 – General, Technical Data
1 Transmission Identification
(Edition 09.2015)
KHN - Transmission Code
Refer to
⇒ “3 Engine Codes, Engine Al‐
location”, page 3
01.06.06 - Production Date:
06/01/2006
14 - Plant Code
13 59 - Time
0026 - Serial Number
The transmission code is also listed on the vehicle data label.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-Speed Dual Clutch Transmission 0AM - Edition 09.2015
1. Transmission Identification 1
ProCarManuals.com

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2 Overview - Transmission
The 7-speed DSG® transmission 0AM has 5 shafts. Two input
shafts and three output shafts.
A1 - Input Shaft 1
A2 - Input Shaft 2
B1 - Output Shaft 1
B2 - Output Shaft 2
B3 - Output Shaft 3
C - Front Final Drive
K1 - Clutch 1
K2 - Clutch 2
M - Engine
T1 - Sub-Transmission 1
❑ With 1st, 3rd, 5th and
7th gears
T2 - Sub-Transmission 2
❑ With 2nd, 4th, 6th and
reverse gears
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-Speed Dual Clutch Transmission 0AM - Edition 09.2015
2 Rep. Gr.00 - General, Technical Data
ProCarManuals.com

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3 Engine Codes, Engine Allocation
Use the transmission code if a repair requires replacement parts.
Allocation: Transmission Codes for Gasoline Engines
Codes KUC, LWE, MDH, MGK, MGU, MLB, MPH,
NAS, NBA, NQA, NQK, NTP, NTZ, PKM,
PKW, PMH, PMS
KHN, LKG, LKM, LPJ, LWZ, MGK, MLB,
MPH, NAS, NQA, NTP, PKM, PMH
Engine 1.2L - 77 kW TSI 1.4L - 90 kW TSI
For the following data. Refer to the Parts Catalog.
♦ The individual gear ratios
♦ Transmission fluid
♦ Clutch allocation
Allocation: Transmission Codes for Gasoline Engines
Codes KUT, LKP, LPL, LWW, MGM, MLD, MPK,
MSL, MUV, NAU, NAZ, NQA, NQJ, NTP, NTX,
PKM, PMH, PMQ
LKJ, LPN, LSU, MGP, MLF, MPM
Engine 1.4L - 118 kW TSI 1.6L - 75 kW MPI
For the following data. Refer to the Parts Catalog.
♦ The individual gear ratios
♦ Transmission fluid
♦ Clutch allocation
Allocation: Transmission Codes for Diesel Engines
Codes KHM, LKF, LKL, LPH, LSR, MGJ LKQ, LQN, LST, MGN, MLE, MPL, NAV,
NQD, NTS, PKP, PMK
Engine 1.9L - 77 kW TDI PD 1.6L - 77 kW TDI Common Rail
For the following data. Refer to the Parts Catalog.
♦ The individual gear ratios
♦ Transmission fluid
♦ Clutch allocation
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-Speed Dual Clutch Transmission 0AM - Edition 09.2015
3. Engine Codes, Engine Allocation 3
ProCarManuals.com

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4 Capacities
The 7-Speed DSG® transmission has two separate, different fluid
systems. One for the transmission fluid -arrow A- and one for the
hydraulic fluid -arrow B-.
Capacities Transmission Fluid
Refill Refer to ⇒ Fluid Capacity Tables; Rep. Gr.
03
Change No change required
Grease Transmission fluid for DSG® transmission
0AM
. Refer to the Parts Catalog for the part num‐
ber.
Capacities Hydraulic fluid in DSG Transmission Mecha‐
tronic - J743-
Refill Refer to ⇒ Fluid Capacity Tables; Rep. Gr.
03
Change Change not possible
Checking the hydraulic fluid level for the
DSG Transmission Mechatronic - J743- is
not possible.
Grease Hydraulic oil
. Refer to the Parts Catalog for the part num‐
ber.
For more details, refer to the part number on the container.
Caution
Risk of damaging the transmission.
♦ Use only the transmission fluid specifically for the 7-speed
DSG® transmission 0AM. It is available as a replacement
part. Refer to the Parts Catalog.
♦ Using other fluids can cause malfunctions or transmission
failure.
♦ Checking the hydraulic fluid level in the DSG Transmis‐
sion Mechatronic - J743- is not possible. The vent on the
DSG Transmission Mechatronic - J743- must be sealed
tight before performing any assembly work.
♦ Fluid that has leaked out of the DSG Transmission Me‐
chatronic - J743- hydraulic area may not be refilled or
checked.
♦ If transmission fluid has leaked out, then it is necessary to
perform a transmission fluid replacement. It is not possible
to check the fluid level.
♦ Underfilling or overfilling both fluid systems will impair the
function of the transmission.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-Speed Dual Clutch Transmission 0AM - Edition 09.2015
4 Rep. Gr.00 - General, Technical Data
ProCarManuals.com

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5 Safety Precautions
⇒ “5.1 General Safety Precautions”, page 5
⇒ “5.2 Safety Precautions when Working on Vehicles with Start/
Stop System”, page 5
⇒ “5.3 Safety Precautions during Road Test with Testing Equip‐
ment”, page 6
5.1 General Safety Precautions
To avoid personal injury and damage to the vehicle, observe the
following:
WARNING
Risk of injury and accident by accidentally engaging a gear with
the engine running.
♦ Move the selector lever into “P” and set the parking brake
before working on a running engine.
To prevent personal injury and damage to the electrical/electronic
components, note the following:
♦ Only connect and disconnect test equipment when the ignition
is off.
Caution
Risk of destroying electronic components when disconnecting
the battery.
♦ Follow the steps when disconnecting the battery.
♦ Always turn off the ignition before disconnecting the bat‐
tery.
– Disconnect the battery. Refer to ⇒ Electrical Equipment; Rep.
Gr. 27 ; Battery; Battery, Disconnecting and Connecting .
5.2 Safety Precautions when Working on
Vehicles with Start/Stop System
Note the following when working on vehicles with a Start/Stop
System:
WARNING
Risk of injury if the engine starts automatically in vehicles with
a Start/Stop System.
♦ For vehicles with an activated Start/Stop System (recog‐
nizable from a notification in the instrument cluster), the
engine can be started automatically if needed.
♦ For this reason make sure the Start/Stop System is disa‐
bled when working on the vehicle (turn off ignition, if
needed, turn the ignition back on).
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-Speed Dual Clutch Transmission 0AM - Edition 09.2015
5. Safety Precautions 5
ProCarManuals.com

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5.3 Safety Precautions during Road Test
with Testing Equipment
Performing road tests while using testing equipment:
WARNING
There is a risk of an accident due to distractions and improperly
secured testing equipment.
The front passenger airbag poses a risk if it deploys during an
accident.
• Operating testing equipment while driving is a distraction.
• Testing equipment that is not secured properly increases
the risk of personal injury.
♦ Always secure testing equipment on the rear seat with a
strap and have a second technician operate it from the
rear seat.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-Speed Dual Clutch Transmission 0AM - Edition 09.2015
6 Rep. Gr.00 - General, Technical Data
ProCarManuals.com

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6 Tow Starting and Towing Notes
Caution
Risk of destroying the transmission.
♦ When towing the vehicle, move the selector lever to “N”.
Do not tow the vehicle farther than 50 km and do not drive
faster than 50 km/h.
Note
The engine cannot be tow-started to start the engine, for example,
if the battery is too weak or if the starter is not working.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-Speed Dual Clutch Transmission 0AM - Edition 09.2015
6. Tow Starting and Towing Notes 7
ProCarManuals.com

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7 General Repair Information
⇒ “7.1 Tools”, page 8
⇒ “7.2 Transmission”, page 8
⇒ “7.3 Working with Vehicle Diagnostic Testers ”, page 13
7.1 Tools
A list of special tools and workshop equipment required for repair
procedures in a manual can be found at the beginning of each
Repair Group section and in the Workshop Equipment and Spe‐
cial Tools catalog.
The catalog is also available on CD-ROM and can be ordered the
standard way through Bertelsmann.
Uncertainties often exist on smaller screws with lower tightening
specifications. The Torque Wrench 1783 - 2-10Nm - VAG1783-
can be used for these bolts.
7.2 Transmission
The flywheel transfers the engine torque to the dual clutch. The
flywheel and the dual clutch are connected to each other via
splines. Together they take over the function of the dual mass
flywheel.
The transmission is built like a 7-speed manual transmission. The
alternating hydraulic actuation of the two dry multi-plate clutches
permits operation similar to that of an automatic transmission.
This means the gears are automatically or manually shifted via
the Tiptronic mode. There is no clutch pedal.
The transmission has an opening in the housing.
Note
This opening is sealed with a cap on some transmissions.
– Make sure that no small pieces fall into this opening -arrow-
during assembly work. Cover the opening with a cloth.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-Speed Dual Clutch Transmission 0AM - Edition 09.2015
8 Rep. Gr.00 - General, Technical Data
ProCarManuals.com

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Always make sure that no dirt enters an »open« transmission.
♦ Do not run the engine when the cover is removed from the
transmission or when there is no transmission fluid in the
transmission. Do not tow the vehicle.
♦ Thoroughly clean the connection points and the area around
them first, and then loosen them.
♦ Make sure that the alignment sleeves between the engine and
transmission are positioned correctly when installing the trans‐
mission.
♦ Place the removed parts on a clean surface and cover them
so that they do not become contaminated. Use foil and paper.
Only use lint-free cloths.
♦ Only install clean components. Install replacement parts im‐
mediately after removing them from their packaging.
♦ Cover all opened components carefully if it necessary to per‐
form a repair.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-Speed Dual Clutch Transmission 0AM - Edition 09.2015
7. General Repair Information 9
ProCarManuals.com

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Some Vehicles Have A Cover Over the Engaging Levers
The cover prevents dirt from getting in.
Tightening specification for bolts: 8 Nm
Overview - Transmission
1 - Transmission ventilation cap
2 - Cover
3 - Selector Lever
4 - DSG Transmission Mechatronic - J743- Bleed Unit
5 - DSG Transmission Mechatronic - J743-
6 - Dual Clutch
7 - Flange Shaft
8 - Oil Drain Plug, 30 Nm
9 - S tronic Transmission
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-Speed Dual Clutch Transmission 0AM - Edition 09.2015
10 Rep. Gr.00 - General, Technical Data
ProCarManuals.com

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.
Selector Mechanism
Similar to an automatic transmission, the selector lever position
is no longer transmitted mechanically to the transmission via the
selector lever cable and the multifunction transmission range
switch (drive position sensor). The selector lever positions and
shifts are transmitted via a separate control module in the selector
mechanism to the transmission control module via the CAN bus.
Shifting occurs without a selector lever cable. The selector lever
cable mechanically brings the parking lock into the selector lever
position “P”.
Transmission Fluid
Only transmission fluids available as replacement part may be
used for the DSG® transmission 0AM. Using other oils can lead
to function problems or can even cause the transmission to fail,
for the specification. Refer to the Parts Catalog.
It is not possible to check the transmission fluid level in the trans‐
mission. A transmission fluid level adjustment can only be done
when replacing the transmission fluid.
Do not reuse drained oil.
Caution
Be very careful when handling transmission fluid. Dispose of
drained transmission fluid correctly.
O-Rings, Gaskets and Seals
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-Speed Dual Clutch Transmission 0AM - Edition 09.2015
7. General Repair Information 11
ProCarManuals.com

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♦ O-rings, gaskets and seals must always be replaced.
♦ The seals for the stub shaft or the flange shaft and drive axle
are also called shaft seals.
♦ After removing seal rings and seals, always inspect the con‐
tact surfaces at housing or shaft for burrs resulting from re‐
moval, or for other signs of damage.
♦ Before installing the seals, lightly oil the outer circumference
and fill the space between the sealing lips -arrow- halfway with
Grease - G 052 128 A1- .
♦ The open side of the gaskets point toward the fluid to be sealed
in.
♦ Coat the O-rings with transmission fluid or Vaseline before in‐
serting to prevent them from being crushed during assembly.
♦ Do not use any other lubricants in the transmission fluid area.
Otherwise there is a danger of the hydraulic transmission con‐
trol malfunctioning.
Circlips
♦ Do not stretch the circlips.
♦ Replace damaged or stretched circlips.
♦ The circlips must rest at the bottom of the groove.
Bolts and Nuts
♦ Loosen or tighten bolts and nuts on the covers or housings
diagonally.
♦ The tightening specifications given apply to unoiled bolts and
nuts.
♦ Use a wire brush to clean the threads of the bolts that were
installed with locking fluid. Install the bolts with Locking Fluid
- AMV 185 101 A1- .
♦ Clean the threaded holes for the self-locking bolts or for the
bolts coated with locking fluid (for example with a thread tap).
Otherwise there is the risk that the bolts could break off the
next time they are removed.
♦ Always replace self-locking bolts and nuts.
Electrical Components
Due to an electrostatic charge to the human body, a person can
receive an electrostatic shock when metal objects are touched.
This charge can damage the electrical/electronic components on
the transmission and the selector mechanism.
– Touch a grounded object, such as, a water pipe or a vehicle
hoist, before working on electrical/electronic components. Do
not touch connector or »open« electronic components directly.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-Speed Dual Clutch Transmission 0AM - Edition 09.2015
12 Rep. Gr.00 - General, Technical Data
ProCarManuals.com

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.
7.3 Working with Vehicle Diagnostic Testers
⇒ “7.3.1 Adapting Installation Information”, page 13
⇒ “7.3.2 Mandatory Reporting Measurements, Reading”,
page 13
⇒ “7.3.3 Basic Measurement, Performing”, page 13
• Use only Volkswagen Vehicle Diagnostic Tester .
♦ Vehicle Diagnostic Tester
♦ Vehicle Diagnostic Tester
♦ Vehicle Diagnostic Tester
The Guided Functions button and the Guided Fault Find-
ing button offer various functions. The 3 most important functions
are:
♦ Adapting Installation Information
♦ Mandatory Reporting Measurements, Reading
♦ Basic Measurement, Performing
7.3.1 Adapting Installation Information
The Mechatronic recognizes other control modules in the vehicle
by signals from the Data bus. Pressing the adapt installation
information button tells the Mechatronic to forget all communi‐
cation partners.
All »active partners« are recognized the next time the ignition is
turned on.
Faults cannot be »generated« with this function. Always use the
Adapt installation information after the following tasks:
♦ After installing a gearshift mechanism.
♦ After a different control module is installed, for example, en‐
gine, ABS or Gateway.
♦ After working on the steering wheel paddle.
7.3.2 Mandatory Reporting Measurements,
Reading
It is necessary to upload the measurements before contacting the
Technical Service Center or the importer.
Save the measurements in the diagnostic log so that all the nec‐
essary transmission data is available for analyzing the faults.
7.3.3 Basic Measurement, Performing
This is how the Mechatronic learns the important settings. Also
important adjustments are learned new or reset to the pre-pro‐
grammed points. Among others, these are the synchronizing
points and the »corner points« for the engaging lever and the gear
selector.
WARNING
Do not perform a basic measurement without cause or without
being requested.
– Press the J743 perform Mechatronic basic measure-
ment screen button only:
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-Speed Dual Clutch Transmission 0AM - Edition 09.2015
7. General Repair Information 13
ProCarManuals.com

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♦ If “Guided Fault Finding” requests it
♦ after having corrected a fault stored in the DTC memory
♦ after have installed a dual clutch
♦ or after having installed a Mechatronic
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-Speed Dual Clutch Transmission 0AM - Edition 09.2015
14 Rep. Gr.00 - General, Technical Data
ProCarManuals.com

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.
30 – Clutch
1 Dual Clutch, Removing and Instal‐
ling, through Transmission Produc‐
tion Date 05/2011
Transport the Transmission and Secure to the Assembly Stand.
Refer to
⇒ “6 Transmission, Transporting and Securing To Assembly
Stand”, page 191 .
Dual Clutch, Removing and Installing, from Transmission Pro‐
duction Date 06/2011. Refer to
⇒ “2 Dual Clutch, Removing and Installing, from Transmission
Production Date 06/2011”, page 40 .
⇒ “1.1 Overview - Dual Clutch, through Transmission Production
Date 05/2011”, page 15
⇒ “1.2 Dual Clutch, Removing, through Transmission Production
Date 05/2011”, page 17
⇒ “1.3 K 1 and K 2 Clutch Engaging Bearing Position, Adjusting,
Transmission Production Date through 05/2011”, page 20
⇒ “1.4 Dual Clutch, Installing, Transmission Production Date
through 05/2011”, page 33
1.1 Overview - Dual Clutch, through Trans‐
mission Production Date 05/2011
Caution
Danger of causing damage to the clutch adjusting tool.
♦ The clutch is self-adjusting. Vibrations can affect the ad‐
justing tool. Be careful not to drop the clutch into the
transmission when installing.
♦ Do not install a clutch that has fallen onto a hard surface
or shows signs of damage.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-Speed Dual Clutch Transmission 0AM - Edition 09.2015
1. Dual Clutch, Removing and Installing, through Transmission Production Date 05/2011 15
ProCarManuals.com

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1 - Circlip
❑ Always replace after re‐
moving
2 - Hub
3 - Circlip
❑ Always replace after re‐
moving
4 - Large Engaging Lever for
“K 1”
❑ With large engaging
bearing
❑ Always replace when
replacing the dual clutch
5 - Small Engaging Lever for
»K 2«
❑ Always replace when
replacing the dual clutch
6 -
Bolts
❑ 8 Nm +90°
❑ Always replace after re‐
moving
7 - Support
❑ For engaging lever
❑ Always replace when
replacing the dual clutch
8 - Bracket
❑ For small engaging lev‐
er
❑ Not equipped on some
older transmissions
❑ Always replace when
replacing the dual clutch
9 - Seal
❑ For the inner input shaft
❑ Replacing. Refer to ⇒ “3 Clutch-Side Seals, Removing and Installing”, page 63 .
10 - Seal
❑ For the outer input shaft
❑ Replacing. Refer to ⇒ “3 Clutch-Side Seals, Removing and Installing”, page 63 .
11 - Outer Input Shaft
12 - Shim “SK 2”
❑ Selecting thickness. Refer to
⇒ “1.3 K 1 and K 2 Clutch Engaging Bearing Position, Adjusting, Transmission Production Date through
05/2011”, page 20 .
13 - Shim “SK 1”
❑ Selecting thickness. Refer to
⇒ “1.3 K 1 and K 2 Clutch Engaging Bearing Position, Adjusting, Transmission Production Date through
05/2011”, page 20 .
14 - Small Engaging Bearing for »K 2«
❑ Refer to
⇒ “1.3 K 1 and K 2 Clutch Engaging Bearing Position, Adjusting, Transmission Production Date through
05/2011”, page 20
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
7-Speed Dual Clutch Transmission 0AM - Edition 09.2015
16 Rep. Gr.30 - Clutch
ProCarManuals.com