Volkswagen Golf 2013 Workshop Manual

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Workshop Manual

Golf 2013 ➤

7-speed dual clutch gearbox 0CW

Edition 10.2012

Service

Service Department. Technical Information

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List of Workshop Manual 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 - 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

No reproduction without prior agreement from publisher.

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Contents

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

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

1.1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.1 Allocation gearbox - engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3 Overview - power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.1 Overview - power transmission - front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4.1 General safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4.2 Safety precautions when working on vehicles with a Start/Stop system . . . . . . . . . . . . . . 6

4.3 Safety precautions when using test and measuring equipment during a road test . . . . . . 7

4.4 Notes on tow-starting/towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

5 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5.2 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

5.3 Gaskets, seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

5.4 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.1 Assembly overview - dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.2 Removing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.3 Installing dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.4 Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.5 Renewing oil seal for inner input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2 Clutch operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.1 Assembly overview - clutch engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.2 Removing and installing clutch engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2.3 Adjusting clutch engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

1 Mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

1.1 Exploded view - mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

1.2 Removing and installing mechatronic unit for dual clutch gearbox J743 . . . . . . . . . . . . . . 42

1.3 Moving mechatronic unit for dual clutch gearbox J743 into removal position by hand . . . . 55

2 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

2.1 Assembly overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

2.2 Emergency release from position P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

2.3 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

2.4 Moving push button to installation position in the handle . . . . . . . . . . . . . . . . . . . . . . . . . . 60

2.5 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

2.6 Removing and installing selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

2.7 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

2.8 Checking and adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

2.9 Renewing oil seal for selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

3 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

3.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

3.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

3.3 Specified torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

4 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Golf 2013 ➤

7-speed dual clutch gearbox 0CW - Edition 10.2012

Contents i

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5 Installing to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

6 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

6.1 Schematic overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

6.2 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

7 Gearbox housing, clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

7.1 Repairing gearbox housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

7.2 Repairing clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

8 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

8.1 Draining and filling gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

1.1 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

2.1 Assembly overview - output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

2.2 Dismantling and assembling output shaft 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

2.3 Dismantling and assembling output shaft 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

2.4 Dismantling and assembling output shaft 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

2.5 Determining shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

3 Parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

3.1 Removing and installing cover for parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

3.2 Removing and installing parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

1 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

1.1 Overview of fitting locations - seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

1.2 Renewing left oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

1.3 Renewing right oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

Golf 2013 ➤

7-speed dual clutch gearbox 0CW - Edition 10.2012

ii Contents

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00 – Technical data

1 Identification

(VRL004860; Edition 10.2012)

⇒ “1.1 Gearbox identification”, page 1

1.1 Gearbox identification

The following information is indicated on the gearbox (example):

♦ KHN = Gearbox code

♦ 01.06.06 = Production date

♦ 14 = Factory code

♦ 13:59 = Production time

♦ 0026 = Serial number

Golf 2013 ➤

7-speed dual clutch gearbox 0CW - Edition 10.2012

1. Identification 1

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Note

The gearbox code also appears on the vehicle data stickers.

Golf 2013 ➤

7-speed dual clutch gearbox 0CW - Edition 10.2012

2 Rep. gr.00 - Technical data

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2 Technical data

⇒ “2.1 Allocation gearbox - engine”, page 3

⇒ “2.2 Capacities”, page 4

2.1 Allocation gearbox - engine

Take account of the gearbox code if spare parts are required for

a repair.

Dual clutch gearbox 0CW

PNA PNA MSP,

PNB

NAR, PMZ PMZ

1.2 l -

77 kW TSI

1.4 l - 90 kW

TSI

1.4 l -

103 kW

TSI

1.6 l - 77,

81 kW TDI

2.0 l -

81 kW TDI

Golf 2013 ➤

7-speed dual clutch gearbox 0CW - Edition 10.2012

2. Technical data 3

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2.2 Capacities

The 7-speed dual clutch gearbox has two separate and different

oil systems. One for the gear oil section -arrow A- and one for the

hydraulic fluid section -arrow B-.

Capacities Gear oil section

Initial filling 1.7 litres

Change No change necessary

Lubricant Gear oil for dual clutch gearbox 0CW

Part number ⇒ Electronic Parts Catalog (ET‐

KA)

Capacities Hydraulic oil part with mechatronic unit for

dual clutch gearbox -J743-

Initial filling 1 litre

Change No fluid change possible

It is not possible to check the fluid level in the

hydraulic section of the mechatronic unit for

dual clutch gearbox -J743- .

Lubricant Hydraulic fluid

Caution

Risk of damage to gearbox.

♦ Only the gear oil for the 7-speed dual clutch gearbox 0CW,

which is available through the replacement parts system,

may be used ⇒ Electronic Parts Catalog (ETKA) .

♦ Other oils will lead to malfunctions or failure of the gear‐

box.

♦ It is not possible to check the fill level of the hydraulic fluid

section of the mechatronic unit for dual clutch gearbox -

J743- . For installation measures, the breather of the

mechatronic unit for dual clutch gearbox -J743- must be

sealed so that no oil can escape ⇒ page 91 . If any oil

escapes from the hydraulic fluid section of the mecha‐

tronic unit for dual clutch gearbox -J743- , it is not possible

to replenish it or check the level!

♦ If oil escapes from the gear oil part, it can only be rectified

by changing the gear oil ⇒ page 121 . It is not possible to

check the fill level.

♦ If the level of oil/fluid is too high or too low in either of the

parts, the function of the gearbox will be impaired.

Golf 2013 ➤

7-speed dual clutch gearbox 0CW - Edition 10.2012

4 Rep. gr.00 - Technical data

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3 Overview - power transmission

⇒ “3.1 Overview - power transmission - front-wheel drive”,

page 5

3.1 Overview - power transmission - front-wheel drive

The 7-speed dual clutch gearbox 0CW equipped with 5 shafts. 2

input shafts and 3 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 - Dual clutch 1

K2 - Dual clutch 2

M - Engine

T1 - Sub-gearbox 1

❑ with gears 1, 3, 5 and 7

T2 - Sub-gearbox 2

❑ with gears 2, 4, 6 and

reverse gear R

Golf 2013 ➤

7-speed dual clutch gearbox 0CW - Edition 10.2012

3. Overview - power transmission 5

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4 Safety instructions

⇒ “4.1 General safety regulations”, page 6

⇒ “4.2 Safety precautions when working on vehicles with a Start/

Stop system”, page 6

⇒ “4.3 Safety precautions when using test and measuring equip‐

ment during a road test”, page 7

⇒ “4.4 Notes on tow-starting/towing”, page 7

4.1 General safety regulations

To prevent personal injury and material damage to the vehicle,

observe the following:

WARNING

Risk of injury and accident by accidental engagement of gear

while engine is running.

♦ Before working on vehicle with engine running, move se‐

lector lever into position “P” and apply parking brake.

To prevent personal injury and damage to or destruction of elec‐

trical and electronic components, observe the following:

♦ Connect and disconnect measuring and testing devices only

with the ignition switched off.

Caution

Danger of destruction of electronic components when battery

is disconnected.

♦ Take the necessary measures when disconnecting the

battery.

♦ Always switch off the ignition before disconnecting the

battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Dis‐

connecting and connecting battery .

4.2 Safety precautions when working on ve‐

hicles with a Start/Stop system

During work on vehicles with Start/Stop system, observe the fol‐

lowing:

WARNING

Injury hazard as a result of automatic engine start in vehicles

with Start/Stop system

♦ In vehicles with the Start/Stop system activated (identifi‐

able by an indication in the dash panel insert) the engine

can start automatically if required.

♦ When working on the vehicle, always make sure that the

Start/Stop system is deactivated (switch off the ignition;

switch the ignition on again if necessary).

Golf 2013 ➤

7-speed dual clutch gearbox 0CW - Edition 10.2012

6 Rep. gr.00 - Technical data

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4.3 Safety precautions when using test and

measuring equipment during a road test

Observe the following if test and measuring equipment is required

during a road test:

WARNING

Accident hazard as a result of distraction and inadequate se‐

curing of test and measuring equipment.

Danger as a result of activation of front passenger airbag in

event of an accident.

• Operation of test and measuring equipment while driving

results in distraction.

• Greater injury hazard as a result of unsecured test and

measuring equipment.

♦ Always secure test and measuring equipment to the rear

seat with a strap and have it operated from there by a

second person.

4.4 Notes on tow-starting/towing

Caution

Danger of irreparable damage to gearbox.

♦ Selector lever must be in “N” position for towing vehicle.

Do not tow for more than 50 km and not faster than 50 km/

h.

Note

It is not possible to tow-start the engine.

Golf 2013 ➤

7-speed dual clutch gearbox 0CW - Edition 10.2012

4. Safety instructions 7

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5 Repair instructions

⇒ “5.1 General notes”, page 8

⇒ “5.2 General repair notes”, page 9

⇒ “5.3 Gaskets, seals”, page 10

⇒ “5.4 Nuts and bolts”, page 10

5.1 General notes

Gearbox

♦ The torque of the engine is transmitted via the flywheel to the

dual clutch gearbox. The flywheel and the dual clutch are

joined together by a toothed connection. Together they take

on the function of the dual-mass flywheel.

♦ The gearbox is structured like a 7-speed manual gearbox.

Through opposed hydraulic actuation of two multi-plate dry

clutches, it is operated like an automatic gearbox. In other

words, the gears are engaged automatically or manually via

the Tiptronic system. There is no clutch pedal.

♦ When the ignition is switched off, both clutches are disengag‐

ed.

Golf 2013 ➤

7-speed dual clutch gearbox 0CW - Edition 10.2012

8 Rep. gr.00 - Technical data

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.

The gearbox has an opening in the housing.

– Ensure that no small parts fall into this opening during repairs

-arrow-. Cover the opening if necessary.

Gearbox oil

The 7-speed dual clutch gearbox has two separate and different

oil systems. One for the gear oil section -arrow A- and one for the

hydraulic fluid section -arrow B-.

Only the types of gear oil available as a replacement part may be

used for the dual clutch gearbox 0CW. Other oils will lead to mal‐

functions or failure of the gearbox, part number ⇒ Electronic Parts

Catalog (ETKA) .

The oil level in the gearbox cannot be checked. The correct gear

oil level can only be achieved by renewing the gear oil, e.g. if the

gearbox is leaking

⇒ “8.1 Draining and filling gear oil”, page 121 .

5.2 General repair notes

♦ To ensure flawless and successful gearbox repairs, the great‐

est care and cleanliness as well as the use of good and proper

tools are essential. Of course, the basic rules for safety also

apply during repair work.

♦ A number of generally applicable instructions for the various

repair procedures which were previously repeated at numer‐

ous places in the workshop manual are summarised here.

They apply to this workshop manual.

Guided fault finding, vehicle self-diagnosis and testing

♦ Before performing repairs on the gearbox, determine the exact

cause using vehicle diagnostic tester Guided fault find-

ing, Vehicle self-diagnosis and Test instruments

modes.

Gearbox

♦ Do not run the engine or tow the vehicle with oil pan removed

or when there is no gear oil in the gearbox.

♦ Thoroughly clean all joints and surrounding areas before dis‐

mantling.

♦ When installing, ensure that the dowel sleeves are fitted cor‐

rectly.

Locking devices

♦ Do not overstretch retaining rings.

♦ Always renew retaining rings which have been damaged or

overstretched.

♦ Retaining rings must locate properly in grooves.

Golf 2013 ➤

7-speed dual clutch gearbox 0CW - Edition 10.2012

5. Repair instructions 9

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5.3 Gaskets, seals

♦ Renew O-rings, seals and gaskets.

♦ After removing gaskets and seals, always inspect contact sur‐

face of housing or shaft for burrs resulting from removal or for

other signs of damage.

♦ Before installing seals, lightly oil outer diameter and half-fill

space between sealing lips -arrow- with sealing grease -

G 052 128 A1- .

♦ The open side of the oil seal faces the side with fluid filling.

♦ Only use DSG transmission oil. Other lubricants will cause

problems in function.

♦ After renewing gaskets, O-rings and seals - drain gear oil

completely and refill with new oil ⇒ page 121 .

5.4 Nuts and bolts

♦ Loosen and tighten securing bolts and securing nut for covers

and housings diagonally.

♦ Specified torques settings are specified for unoiled bolts and

nuts.

♦ Threads of bolts secured with locking fluid must be cleaned

with a wire brush. Then insert bolts with locking fluid -

AMV 185 101 A1- .

♦ Threaded holes into which self-locking bolts or bolts coated

with locking fluid are screwed, must be cleaned (e.g. with a

thread chaser). Otherwise there is a danger of bolts shearing

when subsequently being removed.

♦ Always renew self-locking bolts and nuts.

Golf 2013 ➤

7-speed dual clutch gearbox 0CW - Edition 10.2012

10 Rep. gr.00 - Technical data

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.

30 – Clutch

1 Clutch

⇒ “1.1 Assembly overview - dual clutch”, page 11

⇒ “1.2 Removing dual clutch”, page 12

⇒ “1.3 Installing dual clutch”, page 16

⇒ “1.4 Renewing input shaft seal”, page 20

⇒ “1.5 Renewing oil seal for inner input shaft”, page 22

1.1 Assembly overview - dual clutch

1 - Hinge mounting

❑ For large engaging lever

“K 1”

❑ Cannot be renewed.

2 - Ball pin

❑ Small small engaging

lever “K 2”

❑ Removing and installing

⇒ page 30 .

3 - Shim “SK 1”

❑ Determining thickness

⇒ page 29

4 - Shim “SK 2”

❑ Determining thickness

⇒ page 29

5 - Small engagement bear‐

ings for “K 2”

6 - Dual clutch

❑ Removing and installing

⇒ page 11 .

7 - Retaining ring

❑ Renew.

8 - Hub

9 - Retaining ring

❑ Renew.

10 - Large engaging lever for

“K 1”

❑ With engagement bear‐

ing

❑ Removing and installing

⇒ page 26 .

11 - Upper section of bushing

❑ Small small engaging lever “K 2”

❑ Is removed and installed together with small engaging lever and lower section of bushing

12 - Small engaging lever for “K 2”

❑ Is removed and installed together with upper and lower section of bushing

❑ Removing and installing ⇒ page 26 .

Golf 2013 ➤

7-speed dual clutch gearbox 0CW - Edition 10.2012

1. Clutch 11

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13 - Bolts

❑ Always renew after removing.

❑ 8 Nm +90°

14 - Lower section of bushing

❑ Small small engaging lever “K 2”

❑ Is removed and installed together with small engaging lever and upper section of bushing

15 - Oil seal for inner input shaft

❑ Renewing ⇒ page 22

16 - Input shaft seal

❑ Renewing ⇒ page 20

1.2 Removing dual clutch

Special tools and workshop

equipment required

♦ Hook -3438-

♦ Engine bung set -VAS

6122-

♦ Support device -T10323-

♦ -T10356/5- from assembly

tool -T10356-

♦ Puller -T10373-

♦ Thrust piece -T10376-

♦ 1 x sealing cap -0AM 325

120 A- and 1 x sealing cap

-02M 409 120- , as an al‐

ternative to engine bung set

-VAS 6122-

Golf 2013 ➤

7-speed dual clutch gearbox 0CW - Edition 10.2012

12 Rep. gr.30 - Clutch

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Removing

Prerequisites:

• Gearbox removed and secured to engine and gearbox jack

⇒ page 90 .

• Mechatronic unit for dual clutch gearbox -J743- built into gear‐

box.

Caution

Risk of damage to gearbox.

When performing repairs, the breather opening on the mecha‐

tronic unit for dual clutch gearbox -J743- (-rear arrow-) and the

gearbox breather (-front left arrow-) must be sealed off to avoid

loss of fluid.

♦ If any oil escapes from the hydraulic fluid section of the

mechatronic unit for dual clutch gearbox -J743- , it is not

possible to replenish it or check the level! It is not possible

to check the fill level of the hydraulic fluid section of the

mechatronic unit for dual clutch gearbox -J743- .

♦ If oil escapes from the gear oil section, it can only be rec‐

tified by changing the gear oil. It is not possible to check

the fill level.

♦ If the level of oil/fluid is too high or too low in either of the

parts, the function of the gearbox will be impaired.

♦ The breather cap on the mechatronic unit is destroyed

during removal and must be renewed.

– Pull off both breather caps -arrows-.

Note

♦

The breather cap on the mechatronic unit is destroyed during

removal and must be renewed.

♦

As an alternative to the engine bung set -VAS 6122- the seal‐

ing cap -02M 409 120- can be used to seal the gearbox. The

mechatronic unit can be sealed using sealing cap -0AM 325

120 A- as an alternative ⇒ Electronic Parts Catalog (ETKA) .

– Seal gearbox breather and breather of mechatronic unit for

dual clutch gearbox -J743- with clean sealing plugs from en‐

gine bung set -VAS 6122- so that no oil can escape.

– Order new breather cap for mechatronic unit for dual clutch

gearbox -J743- ; breather cap must be renewed after installing

gearbox ⇒ Electronic Parts Catalog (ETKA) .

• Once the gearbox has been installed in the vehicle, the sealing

plugs must be removed and the breather caps reinstalled, or

new ones must be fitted if necessary.

Golf 2013 ➤

7-speed dual clutch gearbox 0CW - Edition 10.2012

1. Clutch 13

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.

– Turn gearbox on engine and gearbox jack upwards together

with clutch.

Note

The clutch is pulled off upwards. The mechatronic unit remains

on the gearbox.

– Remove retaining ring -arrow- for hub.

– Remove hub with hook -3438- and a screwdriver.

Note

If parts of clutch are renewed, the position of engagement bear‐

ings “K 1” and “K 2” must be set later. It is therefore advisable to

determine dimension “B” for the measurements now

⇒ page 29 .

– Remove

circlip -arrow- for clutch.

If retaining ring cannot be removed:

Note

♦

If the retaining ring cannot be removed it is because the clutch

has »clamped« the retaining ring at the bottom.

♦

In this case, push the clutch down slightly (see following de‐

scription) and release the load on the retaining ring. Never

strike the clutch or shaft with a hammer!

Golf 2013 ➤

7-speed dual clutch gearbox 0CW - Edition 10.2012

14 Rep. gr.30 - Clutch

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.

– Position support bracket -T10323- parallel to gearbox flange

as shown in illustration.

– If necessary, balance out gaps using -T10356/5- , for example.

– Screw in bolts -A- hand-tight.

Note

Bolts -A-, secure with nut as required.

Caution

Risk of damage to clutch and other components!

• Push down clutch using only very light force.

– To press down, turn spindle against thrust piece -T10376- .

– Remove retaining ring -arrow- for clutch.

Note

It is not permissible to reuse the retaining ring.

Continuation once retaining ring has been removed:

– Insert puller -T10373- into clutch and bore out clutch.

– Remove clutch together with puller -T10373- .

Golf 2013 ➤

7-speed dual clutch gearbox 0CW - Edition 10.2012

1. Clutch 15

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.

1.3 Installing dual clutch

Special tools and workshop equipment required

♦ Support device -T10323-

♦ -T10356/5- from assembly tool -T10356-

♦ Puller -T10373-

♦ Thrust piece -T10376-

Golf 2013 ➤

7-speed dual clutch gearbox 0CW - Edition 10.2012

16 Rep. gr.30 - Clutch

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Volkswagen Golf 2013 Workshop Manual

Volkswagen Golf 2013 Workshop Manual

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