Volkswagen Golf Variant 2007 Workshop Manual Download Page 57

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Note

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The clutch is self-adjusting. Shocks can have an effect on this

adjusting device. Even if the mechatronic unit has been re‐

moved, the “sudden removal” of the assembly lever -T10407-

from under the engaging levers can have a negative effect on

the adjusting mechanism.

♦

In order to remove the mechatronic unit, sufficient space must

be available in front of the gearbox. In some vehicles, parts

must be removed which do not have anything to do directly

with the gearbox. Remove any charge air lines or coolant lines

that may be present.

♦

Any retainers fitted on the cover of the mechatronic unit must

also be removed.

♦

A “new” mechatronic unit is correctly filled with oil.

♦

Do not drain oil. A “removed” mechatronic unit is sent back

with its oil in.

Mechatronic unit remains filled with oil.
Removing:
– Raise vehicle. All 4 supports of lifting platform must be at same

height.

– Move selector lever to position “P” position.
– Remove noise insulation ⇒ Rep. Gr. 50 ; Assembly overview

- noise insulation .

– Connect vehicle diagnostic tester and then select “7-speed

dual clutch gearbox”,

Moving gear actuator into -neu-

tral- position

under

Guided functions

– Switch off ignition.
– Raise vehicle.
– Remove complete air filter housing.
♦ Vehicles with petrol engines ⇒ Rep. Gr. 24 ; Removing and

installing air filter

♦ Vehicles with diesel engines ⇒ Rep. Gr. 23 ; Removing and

installing air filter

– Remove battery and battery tray ⇒ Rep. Gr. 27 ; Battery;

Removing and installing battery .

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

7-speed dual clutch gearbox 0AM - Edition 07.2010

3. Mechatronic unit for dual clutch gearbox J743

Summary of Contents for Golf Variant 2007

Page 1: ...swagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Workshop Manual Golf Variant 2007 Golf Variant 2010 Jetta 2005 Jetta 2011 7 speed dual clutch gearbox 0AM Edition 07 2010 Service Service Department Technical Information ...

Page 2: ... Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups Repair Group 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...

Page 3: ...or 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 wi...

Page 4: ... l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 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 Golf Variant 2007 Golf Variant 2010 Jetta 2005 Jett...

Page 5: ... a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 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 Golf Variant 2007 Golf Variant 2010 Jetta 2005 Jetta 2011 7 speed dual cl...

Page 6: ...h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 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 Golf Variant 2007 Golf Varian...

Page 7: ...c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 3 Capacities Dual clutch gearbox 0AM Mechatronic unit for dual clutch gearbox J743 1 7 l gear oil G 052 171 1 l central hydraulic oil and power steering oil G 004 000 Further information in the part number designates the container size Golf Variant 2007 Golf Varia...

Page 8: ... e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 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 Golf Variant 2007 Golf Variant 2010 Jetta 2...

Page 9: ...hat 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 p...

Page 10: ...ain 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 5053 Various functions ar...

Page 11: ...e steering wheel paddle 4 4 2 Reading measured values for mandato ry reporting You must read these measured values before contacting your 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 impo...

Page 12: ...s 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 pleas...

Page 13: ...rac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Support device T10323 Assembly tool T10356 Puller T10373 Thrust piece T10376 Remove gearbox page 73 Golf Variant 2007 Golf Variant 2010 Jetta 2005 Jetta 2011 7 speed dual clutch gearbox 0AM Edition 07 2010 1 Re...

Page 14: ...i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 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 scre...

Page 15: ...etaining 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...

Page 16: ... y r i g h t b y V o l k s w a g e n A G 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 Spe...

Page 17: ...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 toler...

Page 18: ...t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 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 Golf Variant 2007 Golf Variant 2010 Jetta 2005 ...

Page 19: ...t b y V o l k s w a g e n A G 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...

Page 20: ...on 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 proc...

Page 21: ...enAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Measure distance from shaft end to gauge block T10374 Golf Variant 2007 Golf Variant 2010 Jetta 2005 Jetta 2011 7 speed dual clutch gearbox 0AM Edition 07 2010 1 Removing and installing th...

Page 22: ...alculation 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 nomin...

Page 23: ... 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 have found correct shim for K 1 Please install this shim during subsequent clutch installation Continue setting for clutch K...

Page 24: ... i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 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 ...

Page 25: ...lculation 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 nomina...

Page 26: ...d 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 WARNING Later on only insert this 1 shim Not 2 shims With this you also have found correct shim for K 2 Please install this shim during subsequent clutch installati...

Page 27: ... o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Assembly tool T10356 Puller T10373 Thrust piece T10376 Adhesive AMV 195 KD1 01 Perform the following steps Caution Do not oil or grease anything Before clutch is installed position of engagement bearings K 1 and K 2 must be set page 12 Golf Variant 2007 Golf Variant 2010 Jetta 2...

Page 28: ...n 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 le...

Page 29: ...ed 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 i...

Page 30: ...lutch 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 Rattl...

Page 31: ...o enable clutch to find its installation position already turn clutch against puller T10373 by hand Now turn clutch by hand without using a tool In this way clutch slides against retaining ring Do not use any other tool Pressing on causes clutch to locate at bottom on input shaft Clutch should only be pulled up far enough for it to contact re taining ring Then insert hub Hub has a large tooth and ...

Page 32: ...t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Insert retaining ring for hub arrow Installation position Joint of ring must point towards hub on clutch Turn clutch by hand and observe small engaging lever whilst turning Engaging levers must remain still in their position whilst this is being done They are not allowed to move up and down If an engaging lever moves up and down...

Page 33: ...i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Remove clutch again in this case page 8 Look at shims arrows precisely Shims must be correctly seated They must not be damaged Remove plugs and put both breather caps arrows back on After the gearbox has been installed you must initiate a basic adjustment using the Vehicle diagnosis testing and information system VAS 5051 pa...

Page 34: ... filled for life Therefore there is no need to check the oil level of this gearbox This explains why there is no oil level check In case of leaks on gearbox find out what is the cause and rectify the faults Raise vehicle Place drip tray under gearbox Then drain all gear oil and fill with new oil Then install the drain plug again If the gearbox is installed you must remove the battery and bat tery ...

Page 35: ... be renewed Remove Bowden cable from ball head Use your hand to press lever to stop in direction of cable sup port bracket Note installation position of lever and remove it from selector shaft If you are unsure refer to this illustration for guidance Unbolt cover Only leaking covers must be renewed If the cover was not leak ing it does not need to be renewed Pour 1 7 l of oil in through opening ar...

Page 36: ...eal in cover with sealing grease G 052 128 A1 Always renew bolt of lever Fit cover and lever again Attach lever again in same position If you are unsure refer to this illustration for guidance Press selector lever cable back onto ball head and install new securing clip A securing clip which has been removed is not allowed to be in stalled again The clip will have lost its internal tension and so i...

Page 37: ...ase on ly the cover needs to be unclipped page 46 Before removal of han dle pull lock button out past its pressure point Secure locking button with a cable tie or appro priate wire against being pressed in This will pre vent lock button from being accidentally pressed into the handle Removing and installing selector lever handle page 46 2 Selector mechanism with selector lever With selector lever ...

Page 38: ...ew after removing 6 Nut 9 Nm Qty 4 7 Selector housing With seal 8 Selector lever cable Bowden cable is not greased Removing and installing page 34 Checking page 43 Adjusting page 43 9 Securing clip Always renew after removing 10 Hexagon flange nut 8 Nm Qty 4 Torque setting selector lever to selector shaft page 30 2 2 Removing and installing selector lever cable vehicles up to 02 2009 Note Followin...

Page 39: ... e n A G Remove securing clip in direction of arrow Securing clips for selector lever cable must always be renewed Remove Bowden cable from ball head Raise vehicle To remove Bowden cable and or selector mechanism heat shield under selector mechanism and if necessary parts of exhaust system must now be removed Rep Gr 26 Re moving and installing parts of exhaust system Remove selector housing beneat...

Page 40: ...VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Selector housing is pushed forwards slightly on cable Golf Variant 2007 Golf Variant 2010 Jetta 2005 Jetta 2011 7 speed dual clutch gearbox 0AM Edition 07 2010 36 Rep Gr 34 Control...

Page 41: ...w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G To remove cable securing tab must be pushed forwards arrow 1 At same time push pin up with a screwdriver arrow 2 Please insert screwdriver from underneath whilst pushing securing tab forwards Golf Variant 2007 Golf Variant 2010 Jetta 2005 Jetta 2...

Page 42: ... o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Clarification Arrow 1 Push tab forwards Arrow 2 Push pin up Remove selector lever cable Remove selector housing from cable Installing Route selector lever cable without tension Also insert into ca ble support bracket on gearbox Do not secure with securing clips yet Do not clip in ball head Golf Var...

Page 43: ...d during in stallation If the sheet metal is bent downwards it may cause noises The cable will vibrate against the sheet metal Observe sheet metal Press it back up in the tunnel during installation Loosen adjustment screw arrow Put selector housing onto cable Insert selector lever cable into selector mechanism Insert cable into bearing and insert pin from above down wards through eye When you have...

Page 44: ...t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Remove selector housing heat shield and exhaust system Rep Gr 26 Removing and installing parts of exhaust sys tem Check cable page 43 Golf Variant 2007 Golf Variant 2010 Jetta 2005 Jetta 2011 7 speed dual clutch gearbox ...

Page 45: ...e on ly the cover needs to be unclipped page 46 Before removal of han dle pull lock button out past its pressure point Secure locking button with a cable tie or appro priate wire against being pressed in This will pre vent lock button from being accidentally pressed into the handle Removing and installing selector lever handle page 46 2 Selector mechanism with selector lever and selector lev er ca...

Page 46: ...compartment it may be necessary to provide instal lation space Often it is necessary to remove air filter In the interior it may be necessary to remove centre console Note Following installation Bowden cable must be checked for ease of movement and be adjusted Move selector lever to position P position Remove selector lever handle page 46 Remove centre console Rep Gr 68 Remove 4 bolts Torque setti...

Page 47: ...3 2 5 Checking selector lever cable Brief description Selector lever cable must be removed from gearbox so that its freedom 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 page 43 Do not grease connections of cabl...

Page 48: ...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 Adjusting Move selector lever in vehicle to P position Adjuster scr...

Page 49: ...n cable with loosened adjusting screw arrow and new securing clip WARNING Be sure that the parking lock is engaged To do this turn both front wheels simultaneously under the car in the same direction until the parking lock can be head to engage The parking lock is engaged when both front wheels cannot be turned in the same direction at the same time Gently push handle of selector lever forwards an...

Page 50: ...or cover and hold to side Depress brake pedal or set handbrake Vehicles up to 02 2009 Press yellow plastic part arrow from right to left Or press on the pin of the solenoid Vehicles from 03 2009 onwards Press onto yellow plastic part arrow 2 8 Removing and installing selector lever handle It is possible with all handles that lock button is pressed into han dle Do not install a handle with the lock...

Page 51: ... upwards to release handle Lock the handle again after installing To do this press the sleeve under the handle back down You only have to remove transport guard from new handles The locking button is already in installation position Pull connector from cover Pull off handle upwards Lock the handle again after installing Press the sleeve under the handle back down In vehicles with lock button at fr...

Page 52: ... km h almost stationary and shifting into selector lever position N solenoid for selector lever lock should only engage after about 1 second Selector lever can not 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 with the lock button pressed So...

Page 53: ...s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Symbols must change from P R N D S to 7 6 5 4 3 2 1 Ignition and light switched on The respective symbol in the shift mechanism cover lights up Selector lever position display Simultaneous illumination of all selector lever position display segments indicates gearbox emergency running mode Golf ...

Page 54: ... 3 Mechatronic unit for dual clutch gear box J743 Safety note on mechatronic unit for dual clutch gearbox J743 page 50 Overview mechatronic unit page 51 Remove mechatronic unit for dual clutch gearbox J743 page 52 Move mechatronic unit for dual clutch gearbox J743 into re moval position by hand page 62 Install mechatronic unit for dual clutch gearbox J743 page 65 View of selector forks with mechat...

Page 55: ... Do not work on pressure accumulator The accumulator is un der pressure and is not allowed to be opened 3 2 Overview mechatronic unit 1 Bolt 10 Nm M8 x 35 Always renew Note 2 Bolt 10 Nm M8 x 90 Always renew 3 Mechatronic unit for dual clutch gearbox J743 Note Take care with the breather when handling the mechatronic unit When doing any work on the mechatronic unit please remove cap arrow from brea...

Page 56: ...llowing steps In order to remove the mechatronic unit sufficient space must be available in front of the gearbox Depending on the vehicle parts must be removed which do not have anything to do directly with the gearbox For example the air filter housing and if present charge air lines or coolant lines Any retainers fitted on the cover of the mechatronic unit must also be removed The vehicle diagno...

Page 57: ... any charge air lines or coolant lines that may be present Any retainers fitted on the cover of the mechatronic unit must also be removed A new mechatronic unit is correctly filled with oil Do not drain oil A removed mechatronic unit is sent back with its oil in Mechatronic unit remains filled with oil Removing Raise vehicle All 4 supports of lifting platform must be at same height Move selector l...

Page 58: ...over the engaging levers The cover prevents dirt getting in Torque setting 8 Nm If this cover is fitted remove it Remove starter Rep Gr 27 Removing and installing starter Release mechatronic unit connector by pulling in direction of arrow and pull off connector Place drip tray under gearbox Drain gear oil then reinstall drain plug page 30 Pull cap off breather and close using a suitable plug to ac...

Page 59: ...ully to check which bolts you are unscrewing Do not unscrew any cover bolts The gearbox is shown here again from the side to make this sit uation clearer The mechatronic unit must be removed The cover does not have to be removed Therefore do not remove more than 7 bolts The next step is difficult Now press both engaging levers of dual clutch away from plung ers of mechatronic unit Otherwise levers...

Page 60: ...genAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Insert assembly lever T10407 to its right Golf Variant 2007 Golf Variant 2010 Jetta 2005 Jetta 2011 7 speed dual clutch gearbox 0AM Edition 07 2010 56 Rep Gr 34 Controls hous...

Page 61: ...doesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Far enough until groove lines up with housing rib arrow Golf Variant 2007 Golf Variant 2010 Jetta 2005 Jetta 2011 7 speed dual clutch gearbox 0AM Edition 07 2010 3 Mechatronic unit for dual cl...

Page 62: ... n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G No further Assembly lever T10407 should make contact with gearbox housing with its entire rear face Caution Housing rib and groove of lever must be flush with one another Do not insert tool as far as stop Apply a bit of force to tip of lever when turning This stops lever from slipping out when turning Go...

Page 63: ... n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Turn assembly lever T10407 anticlockwise In this way engag ing levers are pressed away from plungers direction of arrow Do not take out assembly lever T10407 It must remain inserted between engaging lever and gearbox housing for the entire proc ess If necessary press assembly lever T10407 against gearbox using a screwdriver G...

Page 64: ...t guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G If lever slips off this indicates you applied a bit of leverage to handle whilst turning Golf Variant 2007 Golf Variant 2010 Jetta 2005 Jetta 2011 7 speed dual clutch gearbox 0AM Edition 07 2010 60 ...

Page 65: ... o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Apply a bit of force to tip of lever when turning This stops lever from slipping out when turning Remove mechatronic unit Mechatronic unit remains filled with oil Make sure no oil runs out of breather Mechatronic unit is to be sent for reconditioning with its oil in If mechatronic unit jams and cannot be removed Golf Va...

Page 66: ...se the gear actuator is caught at the top left of the gearbox housing In this case mechatronic unit is not allowed to be removed with significant force First reposition mechatronic unit on gearbox housing and se cure it with one bolt Move mechatronic unit into removal position by hand page 62 Installing mechatronic unit page 65 3 4 Moving mechatronic unit for dual clutch gearbox J743 into removal ...

Page 67: ...ly if you cannot set the mechatronic unit to removal position with the vehicle diagnostic tester you must move the unit by hand to this position The sticking gear actuator arrow can be pressed by hand into its removal position To do this push a selector fork behind the parking lock cover How to do this is described in the following work procedure First reposition mechatronic unit on gearbox housin...

Page 68: ...emove Bowden cable from ball head Use your hand to press lever to stop in direction of cable sup port bracket Remove lever of selector shaft Unbolt cover Caution The mechatronic unit will not be stuck after the next step That means that it could fall out If not already done Secure me chatronic unit on gearbox with a bolt to prevent it from falling down Working through opening push selector fork to...

Page 69: ...A1 Fit cover and lever again Press selector lever cable back onto ball head and install new securing clip Securing clips for selector lever cable must always be re newed Add gear oil after completing work on mechatronic unit Fill oil into gearbox page 30 Adjust selector lever cable page 43 Place plug on removed mechatronic unit This way the mechatronic unit can be sent sealed in oil tight con diti...

Page 70: ...m e n t C o p y r i g h t b y V o l k s w a g e n A G Note A new mechatronic unit is correctly filled with oil Do not drain oil A removed mechatronic unit is sent back with its oil in Installing All selector forks must be in neutral prior to installation of mechatronic unit Note Make sure that all selector forks are located in N in the middle and therefore that the gearbox is in neutral Therefore ...

Page 71: ...ted Also move each fork into each position in succession Then disengage all gears and return selector forks to middle position neutral Note Neutral neutral neutral or gearbox will not function You can turn the front gear slightly for assistance This makes it easier to shift the forks Please clean sealing surface where mechatronic unit will make contact later on Oil residues on sealing surface will...

Page 72: ...w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Caution Handle with care When levering the plungers out of the me chatronic unit make sure that you do not brace yourself on the sensors Please clean sealing surface of mechatronic unit Golf Variant 2007 Golf Variant 2010 Jetta 2005 Jetta 2011 7 ...

Page 73: ...ripping and putting on make sure selector forks are not inadvertently pressed out of their position Also observe engaging levers and plungers on mechatronic unit Screw in 7 new bolts and tighten until finger tight Remove guide pins T10406 again Make sure that plungers meet up correctly in cups of engaging levers Pull out plungers by hand until they are seated in cups Plungers can be moved into pos...

Page 74: ... C o p y r i g h t b y V o l k s w a g e n A G Turn assembly lever T10407 clockwise and remove it Install gearbox input speed sender 3 G641 Look at sender Clip must not be damaged Sender lug must be fully and firmly in contact with gearbox housing If sender is loose or clip is broken renew mecha tronic unit Remove plug and put breather cap arrow in place Join connector of mechatronic unit Attach a...

Page 75: ... starter Fit charge air or coolant hoses as necessary Install battery and battery tray Rep Gr 27 Battery Re moving and installing battery Install complete air filter housing Vehicles with petrol engines Rep Gr 24 Removing and installing air filter Vehicles with diesel engines Rep Gr 23 Removing and installing air filter If necessary top up coolant Rep Gr 19 Draining and filling coolant Install noi...

Page 76: ... n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 3 6 View of selector forks with mechatronic unit removed N Idling gearbox neutral po sition in the middle R Reverse gear If reverse gear is engag ed extended plunger of mechatronic unit catch es behind gearbox housing Therefore move me chatronic unit into re moval position by hand page 65 1 Gear 2 Gear 3 Gear 4 Gear 5 Gea...

Page 77: ...I CR engine page 97 4 1 Information about gearboxes with differ ent output shafts Gearbox with different output shafts A Stub shafts to 11 2008 B Flange shafts from 12 2008 Vehicles with stub shafts on gearbox To remove gearboxes with stub shafts it is necessary to remove stub shafts Only shafts with straight joints can be put back onto the output shafts safely Therefore these drive shafts must be...

Page 78: ...t b y V o l k s w a g e n A G 4 2 Removing gearbox vehicles with 1 4 l 90 kW TFSI engine and 1 4 l 118 kW TSI engine Special tools and workshop equipment required Support bracket 10 222 A Adjustment plate 3282 59 Adapter 10 222 A 8 Insert tool 18 mm T10179 Gearbox support 3282 Socket T10061 Engine and gearbox jack V A G 1383 A Brief description The gearbox is removed downwards separately without e...

Page 79: ...in vehicles with stub shafts Note After loosening centre bolt do not lower vehicle to ground again Step on the brake pedal while a 2nd mechanic loosens the two drive shaft bolts arrow Remove both front wheels Continuation for all vehicles Remove complete air filter housing Rep Gr 24 Removing and installing air filter Remove battery and battery tray Rep Gr 27 Battery Removing and installing battery...

Page 80: ... i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Release mechatronic unit connector by pulling and pull off connector Now remove all upper connecting bolts between engine and gearbox These tools are appropriate for this Golf Variant 2007 Golf Variant 2010 Jetta 2005 Jetta 2011 7 speed du...

Page 81: ...10061 can be used instead of an 18 mm socket Remove noise insulation Rep Gr 50 Assembly overview noise insulation Remove front part of wheel housing Rep Gr 66 Assembly overview front wheel housing Remove all retainers and brackets from front of gearbox Remove pendulum support Only in vehicles with stub shafts Remove both drive shafts Rep Gr 40 Removing and installing drive shafts Only in vehicles ...

Page 82: ...rive shaft into wheel housing onto longitudinal member This will keep the shaft out of the way during further work The surface protection of the shafts must not be damaged Plastic cable ties or a pair of tensioning straps T10038 are therefore very good for this Secure both drive shafts to suspension struts using tensioning straps T10038 Remove right flange shaft of gearbox Bolt has a 6 mm hexagon ...

Page 83: ...olts 1 and 2 for bracket Then lower engine and gearbox slightly using spindles of sup port bracket 10 222 A so that bracket can be removed At most 5 turns are sufficient to remove bracket In many cases the spindle does not need to be lowered further for the later removal of the gearbox To remove gearbox 0AM set up gearbox support 3282 with ad justment plate 3282 59 and push onto engine and gearbox...

Page 84: ...arated from the engine in this position Remove remaining engine gearbox connecting bolts Press gearbox off engine observing selector lever cable and lower gearbox Note Distance between engine flange and gearbox flange should be about 50 mm before gearbox is lowered Be careful of all lines and coolant hoses when lowering gear box Renew needle bearing in crankshaft arrow Rep Gr 13 Crankshaft pulling...

Page 85: ... r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 4 3 Removing gearbox vehicles with 1 6 l 75 kW MPI engine Special tools and workshop equipment required Support bracket 10 222 A Adjustment plate 3282 59 Adapter 10 222 A 8 Insert tool 18 mm T10179 Gearbox support 3282 Socket T10061 Bracket T10346 Golf Variant 2007 Golf Variant 20...

Page 86: ...oved downwards separately without engine The battery air filter and starter are removed from above Noise insulation beneath engine gearbox lower cover in front left wheel housing and pendulum support are removed from below Perform the following steps Raise vehicle All 4 supports of lifting platform must be at same height Move selector lever to position P position Remove complete air filter housing...

Page 87: ... n A G Remove securing clip in direction of arrow Securing clips for selector lever cable must always be renewed Remove Bowden cable from ball head Cable may also be pushed slightly backwards out of cable support bracket and removed later when gearbox is lowered But then observe cable when lowering gearbox Release mechatronic unit connector by pulling and pull off connector Now remove all upper co...

Page 88: ...e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G A bolt is located in the starter motor hole Bit T10061 can be used instead of an 18 mm socket Remove noise insulation Rep Gr 50 Assembly overview noise insulation Remove front part of wheel housing Rep Gr 66 Assembly overview front wheel housing Golf Variant 2007 Golf Variant...

Page 89: ... Remove pendulum support If fitted remove the heat shield over the right hand drive shaft Tightening torque Rep Gr 40 Repairing drive shafts Disconnect left and right hand drive shafts from flanges on gearbox Unbolt only left suspension link from swivel joint arrows Swing left drive shaft into wheel housing onto longitudinal member This will keep the shaft out of the way during further work The su...

Page 90: ... u m e n t C o p y r i g h t b y V o l k s w a g e n A G Secure both drive shafts to suspension struts using tensioning straps T10038 Remove right flange shaft of gearbox Bolt has a 6 mm hexagon socket Bolt can also be removed and installed with socket V A G 1669 Torque setting 30 Nm Unbolt exhaust system bracket from subframe Remove front exhaust pipe so that lower bolts can be removed arrows Rem...

Page 91: ...A G Bolt bracket T10346 to rear of the 3 mounting holes for bat tery tray To do this use a collar bolt M 6 or a securing bolt for battery tray If there are hose and cable connections in area of engine sup port eye for support bracket 10 222 A remove these now Set up support bracket 10 222 A in front of bonnet support Use Adapter 10 222 A 8 Adapter 10 222 A 3 Place adapters 10 222 A 8 on upper long...

Page 92: ... V A G 1383 A Align arms of gearbox support according to holes in adjust ment plate 3282 59 Screw in support elements as illustrated on adjustment plate 3282 59 Position engine and gearbox jack V A G 1383 A under vehi cle Arrow on adjustment plate 3282 59 points in direction of trav el Align gearbox support 3282 parallel to gearbox Screw pin 3282 29 into rear hole for pendulum support Place both r...

Page 93: ... h t b y V o l k s w a g e n A G Renew needle bearing in crankshaft arrow Rep Gr 13 Crankshaft pulling needle bearing from crankshaft and driving in Transporting gearbox and securing to assembly stand page 111 Installing gearbox page 104 If gearbox is to be sent In some cases there are retainers on the front of the gearbox Remove retainers if installing a new gearbox because there are no retainers...

Page 94: ...i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 4 4 Removing gearbox vehicles with 1 9 l 77 kW TDI PD engine Special tools and workshop equipment required Support bracket 10 222 A Adjustment plate 3282 59 Adapter 10 222 A 8 Socket T10061 Gearbox support 3282 Insert tool 18 mm T10179 Special tools and workshop equipment required Adapter 10 222 A 16 Go...

Page 95: ... gearbox jack V A G 1383 A Brief description The gearbox is removed downwards separately without engine The battery air filter and starter are removed from above Noise insulation beneath engine gearbox lower cover in front left wheel housing and pendulum support are removed from below Perform the following steps Raise vehicle All 4 supports of lifting platform must be at same height Move selector ...

Page 96: ...using Rep Gr 23 Removing and installing air filter Remove battery and battery tray Rep Gr 27 Battery Removing and installing battery Remove starter Rep Gr 27 Removing and installing starter Remove securing clip in direction of arrow Securing clips for selector lever cable must always be renewed Remove Bowden cable from ball head Cable may also be pushed slightly backwards out of cable support brac...

Page 97: ...r i g h t b y V o l k s w a g e n A G Remove noise insulation Rep Gr 50 Assembly overview noise insulation Remove front part of wheel housing Rep Gr 66 Assembly overview front wheel housing Only in vehicles with stub shafts Remove both drive shafts Rep Gr 40 Removing and installing drive shafts Only in vehicles with flange shafts If fitted remove the heat shield over the right hand drive shaft Tig...

Page 98: ...nto wheel housing onto longitudinal member This will keep the shaft out of the way during further work The surface protection of the shafts must not be damaged Plastic cable ties or a pair of tensioning straps T10038 are therefore very good for this Secure both drive shafts to suspension struts using tensioning straps T10038 Remove right flange shaft of gearbox Bolt has a 6 mm hexagon socket Bolt ...

Page 99: ...nections in area of engine sup port eye for support bracket 10 222 A remove these now Remove filler pieces from upper edges of both wings Support engine and gearbox with support bracket 10 222 A but do not raise Secure shackle 10 222 A 16 to gearbox housing Remove all bolts 1 and 2 for bracket Then lower engine and gearbox slightly using spindles of sup port bracket 10 222 A or adapter 10 222 A 16...

Page 100: ...2 parallel to gearbox Screw pin 3282 29 into rear hole for pendulum support Place both remaining attachments onto gearbox as shown When doing this place sheet metal of drift under gearbox housing and not under mechatronic unit Secure gearbox with tensioning strap T10038 Raise gearbox and engine support V A G 1383 A from below to support gearbox The gearbox is separated from the engine in this posi...

Page 101: ... s w a g e n A G In some cases there are retainers on the front of the gearbox Remove retainers if installing a new gearbox because there are no retainers on a new gearbox Install right flange shaft of gearbox with flange shafts page 118 4 5 Removing gearbox vehicles with 1 6 l 77 kW TDI CR engine Special tools and workshop equipment required Support bracket 10 222 A Adjustment plate 3282 59 Socke...

Page 102: ...arbox jack V A G 1383 A Brief description The gearbox is removed downwards separately without engine The battery air filter and starter are removed from above Noise insulation beneath engine gearbox lower cover in front left wheel housing and pendulum support are removed from below Perform the following steps Raise vehicle All 4 supports of lifting platform must be at same height Move selector lev...

Page 103: ... installing battery Remove starter Rep Gr 27 Removing and installing starter Remove securing clip in direction of arrow Securing clips for selector lever cable must always be renewed Remove Bowden cable from ball head Cable may also be pushed slightly backwards out of cable support bracket and removed later when gearbox is lowered But then observe cable when lowering gearbox Release mechatronic un...

Page 104: ...c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Remove noise insulation Rep Gr 50 Assembly overview noise insulation Remove front part of wheel housing Rep Gr 66 Assembly overview front wheel housing If fitted remove the heat shield over the right hand drive shaft Tightening torque Rep Gr 40 Repairing drive shafts Golf Variant 2007 Go...

Page 105: ...ive shaft into wheel housing onto longitudinal member This will keep the shaft out of the way during further work The surface protection of the shafts must not be damaged Plastic cable ties or a pair of tensioning straps T10038 are therefore very good for this Secure both drive shafts to suspension struts using tensioning straps T10038 Remove right flange shaft of gearbox Bolt has a 6 mm hexagon s...

Page 106: ...e n t C o p y r i g h t b y V o l k s w a g e n A G Remove pendulum support If there are hose and cable connections in area of engine sup port eye for support bracket 10 222 A remove these now Remove filler pieces from upper edges of both wings Support engine and gearbox with support bracket 10 222 A but do not raise Place adapters 10 222 A 8 on upper longitudinal carriers directly before the rais...

Page 107: ...ng to holes in adjust ment plate 3282 59 Screw in support elements as illustrated on adjustment plate 3282 59 Position engine and gearbox jack V A G 1383 A under vehi cle Arrow on adjustment plate 3282 59 points in direction of trav el Align gearbox support 3282 parallel to gearbox Screw pin 3282 29 into rear hole for pendulum support Place both remaining attachments onto gearbox as shown When doi...

Page 108: ...aring from crankshaft and driving in Transporting gearbox and securing to assembly stand page 111 Installing gearbox page 104 If gearbox is to be sent In some cases there are retainers on the front of the gearbox Remove retainers if installing a new gearbox because there are no retainers on a new gearbox Install right flange shaft of gearbox with flange shafts page 118 4 6 Installing gearbox Pleas...

Page 109: ...r the engaging levers The cover prevents dirt getting in Torque setting 8 Nm Gearbox with stub shafts A Gearbox with flange shafts B In gearboxes with flange shafts flange shaft must be reinstal led on new gearbox in some cases page 114 Note There is no need to renew oil seal for flange shaft when doing this Remove right hand flange shaft of gearbox in order to install gearbox Gearbox with flange ...

Page 110: ...sible into its cable support bracket Check Bowden cable as soon as gearbox is raised Be sure to insert it in cable support bracket early Bowden cable must not be greased It must be possible to guide the engine and gearbox together by hand until the engine flange and gearbox flange make contact all around If not something has gone wrong Readjust gearbox support until engine and gearbox are aligned ...

Page 111: ... selector lever cable page 43 Carrying out basic adjustment page 7 Torque settings for gearbox installation page 107 4 7 Torque settings Gearbox to engine and notes on assembly mounting The next chapters list the torque settings for gearbox installa tion There is also information about the left assembly mounting Threaded connections that are not directly assigned to the gear box can be found in th...

Page 112: ...s 2 are tightened Torque setting of bolts 2 60 Nm 90 Starter to gearbox Rep Gr 27 Removing and installing start er Pendulum support to subframe and gearbox Rep Gr 40 Assembly overview subframe anti roll bar suspension links Gearbox to engine 1 4 l 90 kW TFSI engine page 108 1 4 l 118 kW TSI engine page 108 1 6 l 75 kW MPI engine page 108 1 9 l 77 kW TDI PD engine page 109 1 6 l 77 kW TDI CR engine...

Page 113: ... t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 4 7 2 Engine 1 9 l 77 kW TDI PD M12 80 Nm If 18 mm insert T10179 is used 65 Nm M10 40 Nm Arrows point towards dowel sleeves Golf Variant 2007 Golf Variant 2010 Jetta 2005 Jetta 2011 7 speed dual clutch gearbox 0AM Editi...

Page 114: ...e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 4 7 3 Engine 1 6 l 77 kW TDI CR M12 80 Nm If 18 mm insert T10179 is used 65 Nm M10 40 Nm Arrows point towards dowel sleeves Golf Variant 2007 Golf Variant 2010 Jetta 2005 Jetta 2011 7 speed dual clutch gearbox 0AM Ed...

Page 115: ... h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 5 Transporting gearbox and securing to assembly stand Transporting gearbox Pull off both breather caps arrows and close using suitable plugs to achieve an oil tight seal Secure gearbox on gearbox support VW 353 Golf Variant 2007 Golf Variant 2010 Jetta 2005 Jetta 2011 7 sp...

Page 116: ...rac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Lift gearbox into assembly stand The gearbox is lifted into assembly stand together with gearbox support VW 353 Golf Variant 2007 Golf Variant 2010 Jetta 2005 Jetta 2011 7 speed dual clutch gearbox 0AM Edition ...

Page 117: ...ranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 35 Gears shafts 1 Currently no repairs can be made to gears and shafts Golf Variant 2007 Golf Variant 2010 Jetta 2005 Jetta 2011 7 speed dual clutch gearbox 0AM Edition 07 2010 1 Currently no repairs can...

Page 118: ... r i g h t b y V o l k s w a g e n A G 39 Final drive front differential 1 Oil seals Gearbox with stub shafts A Right page 114 Left page 116 Gearbox with flange shafts B Right page 118 Left page 120 1 1 Renewing oil seal for right stub shaft Left hand side page 116 Special tools and workshop equipment required Thrust piece 3305 Hexagon key T10107 A or socket and extended bit V A G 1669 Torque wren...

Page 119: ... bevel gears turn it is difficult to reinstall the securing bolts for the stub shafts Remove drive shaft Rep Gr 40 Removing and installing drive shafts Place drip tray under gearbox Remove bolt arrow in stub shaft with socket T10107 A or socket V A G 1669 Pull out stub shaft Pry seal out using assembly lever Lightly oil outer circumference of new oil seal Half fill space between sealing lip and du...

Page 120: ... c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 2 Renewing oil seal for left stub shaft Right side page 114 Special tools and workshop equipment required Thrust piece 3305 Hexagon key T10107 A or socket and extended bit V A G 1669 Multipurpose tool 771 Puller hooks 771 37 Torque wrench V A G 1331 Golf Variant 2007 Golf Variant 2010...

Page 121: ...the op posite front wheel fixed for removing or installing the bolts of the stub shafts Do not remove both stub shafts from gearbox at the same time If the differential bevel gears turn it is difficult to reinstall the securing bolts for the stub shafts Remove drive shaft Rep Gr 40 Removing and installing drive shafts Place drip tray under gearbox Remove bolt arrow in stub shaft with socket T10107...

Page 122: ...s a new dust ring onto the stub shaft using drift sleeve 40 20 Do not use a hammer Insert stub shaft Tighten new countersunk bolt for stub shaft to 30 Nm Reinstall drive shaft Rep Gr 40 Removing and installing drive shafts Renew gear oil page 30 Install noise insulation torque settings Rep Gr 50 As sembly overview noise insulation 1 3 Renewing seal for right flange shaft Left hand side page 120 Sp...

Page 123: ...from gearbox and lay to side Drive shaft is fixed onto suspension strut with tensioning belt T10038 You do not need to remove the centre bolt of the drive shaft Remove noise insulation Rep Gr 50 Assembly overview noise insulation Remove drive shaft heat shield from engine arrows if fitted Unbolt drive shaft from gearbox Place drip tray under gearbox Raise drive shaft as high as possible and secure...

Page 124: ...eing careful not to cant seal Insert flange shaft Tighten new countersunk bolt to 30 Nm When doing this press flange shaft against gearbox so that bolt engages in thread Fit drive shaft back on Rep Gr 40 Removing and installing drive shafts Renew gear oil page 30 Install noise insulation torque settings Rep Gr 50 As sembly overview noise insulation 1 4 Renewing oil seal for left flange shaft Right...

Page 125: ...lange shafts at the same time If the differential bevel gears turn it is difficult to reinstall the bolts Remove drive shaft from gearbox and carefully lay to side Drive shaft is fixed onto suspension strut with tensioning belt T10038 You do not need to remove the centre bolt of the drive shaft Remove noise insulation Rep Gr 50 Assembly overview noise insulation Remove left wheel housing liner Rep...

Page 126: ...ling rod 3 Rep Gr 40 As sembly overview subframe anti roll bar suspension links Pull off coupling rod and turn anti roll bar 2 upwards slightly Swing left drive shaft into wheel housing Raise drive shaft as high as possible and secure Take care not to damage paint on drive shaft in the process Place drip tray under gearbox Remove left flange shaft of gearbox Bolt has a 6 mm hexagon socket Bolt can...

Page 127: ...ust lip of new seal with sealing grease G 052 128 arrow Drive in new seal to stop with thrust piece 3305 being careful not to cant seal Insert flange shaft Tighten new countersunk bolt to 30 Nm When doing this press flange shaft against gearbox so that bolt engages in thread Fit drive shaft back on Rep Gr 40 Removing and installing drive shafts Fit suspension link and coupling rod back on Rep Gr 4...

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