Volkswagen Golf Service & Repair Manual: Removing gearbox

Volkswagen Golf Service & Repair Manual / 7- speed dual clutch gearbox 0CW / Gearbox mechanism, operation, contruction, diff / Removing and installing gearbox / Removing gearbox

Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, Golf SV 2015 ►, vehicles with petrol engine

Brief description

The gearbox is removed downwards separately.

»From above«

Remove battery, air filter and starter. The engine and gearbox must be supported before the left subframe mounting is removed.

»From below«:

Remove -subframe- together with -pendulum support- and -both suspension links-. The -steering rack- remains installed in the vehicle.

Both drive shafts are disconnected from gearbox and left installed in wheel bearing housings. They are only swivelled to one side and left on vehicle.

Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, Golf SV 2015 ►, vehicles with petrol engine

Special tools and workshop equipment required

Support bracket -10 - 222 A-

Adjustment plate -3282/59-

Tensioning strap -T10038-

Shackle -10 - 222 A /12-

Gearbox support -3282-

Engine and gearbox jack -VAS 6931- or -V.A.G 1383 A-

Adapter -10 - 222 A /29-

Engine support basic set -T40091-

Engine support supplement set -T40093-

Not required: Engine support supplementary set -T40093/3-5-

Shock absorber set -T10001-

Removal lever -80 - 200-

Removal lever -80 - 200

Insert tool, 18 mm -T10179-

Insert tool, 18 mm -T10179

Check adapter -T40093/3-6- and adjust as necessary → Fig.

or Adapter -T40093/3-6A-

Check adapter -T40093/3-6- and adjust as necessary

–	If necessary, cut off the marked area.

–	Round off the front edges.

–	Protect adapter against corrosion.

–	Then, mark adapter -T40093/3-6- with -T40093/3-6A-.

At a later point, support bracket -10-222 A- will be put onto longitudinal members with adapters -T40093/3-6A-.

To prevent damage to longitudinal member, cover front area of adapter -T40093/3-6A- with textile-reinforced adhesive tape → Electronic Parts Catalogue (ETKA chemical substances).

Removing

–	Raise vehicle. All 4 supports of lifting platform must be at same height.

–	Move selector lever to position »P«.

–	Remove air filter housing → Rep. gr.24.

–	Remove battery and battery tray → Electrical system; Rep. gr.27.

Check adapter -T40093/3-6- and adjust as necessary

–	Using removal lever -80 - 200-, lever selector lever cable -1- off gearbox selector lever.

–	Remove bolts -2-, raise and tie selector lever cable together with support bracket.

Caution

Risk of damage to selector lever cable.

Do not bend or kink selector lever cable.

–	Remove starter → Electrical system; Rep. gr.27.

It is advisable to remove the »lower« bolt first.

Caution

Risk of damaging gearbox components beyond repair.

Do not under any circumstances touch the contacts in the gearbox connector by hand. Electrostatic discharge can seriously damage the control unit and mechatronic unit.

–	Touch earth connection (without gloves) in order to discharge yourself.

Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, Golf SV 2015 ►, vehicles with petrol engine

–	Disconnect electrical connector -1- for mechatronic unit for dual clutch gearbox -J743-. To do this, pull locking mechanism upwards -arrow-.

–	Unscrew nuts -2- and -3- and remove wiring retainer from gearbox.

–	Tie up wiring in area of gearbox cover.

Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, Golf SV 2015 ►, vehicles with petrol engine

–	Unscrew upper engine/gearbox connecting bolts with a suitable socket from shock absorber set -T10179- or insert tool 18 mm -T10001-.

–	If there are hose and cable connections in area of engine support eye for support bracket -10-222A-, remove these now.

–	Install support bracket -10-222 A- as follows:

Required material:

Adapter -10 - 222 A /29-, qty. 2

Square tube -T40091/1-

Connecting piece -T40091/3-

Spindle from engine support supplement set -T40093 /3-

Shackle -10 - 222 A /12-

Adapter -T40093/3-6A-

Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, Golf SV 2015 ►, vehicles with petrol engine

–	On both sides of vehicle, insert adapters -10 - 222 A /29- between upper wheel housing longitudinal member and mounting plate for wing located underneath.

Installation position:

“L”-1-adapter is to be used on “right” side of vehicle (adapter engages in recess of wing).

“R” (not illustrated here) adapter is to be used on “left” side of vehicle.

Arrow -2- points in direction of travel.

Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, Golf SV 2015 ►, vehicles with petrol engine

–	Slide connecting piece -T40091/3- onto support bracket -10-222 A-.

–	Secure support bracket -10-222 A- to adapters -10 - 222 A /29-.

-A- = adapter -T40093/3-6A- (⇒ next Fig.).

Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, Golf SV 2015 ►, vehicles with petrol engine

–	Position adapter -T40093/3-6A- on left longitudinal member directly behind filler pipe for washer fluid reservoir.

The adapter -T40093/3-6A- is locked with the pins -A- behind the web of the longitudinal member -arrow-.

–	Bolt on spindle from engine support supplement set -T40093 /3-, connect it via square tubes -T40091/1- to engine support bracket -10-222 A- and fasten the connection (⇒ previous fig.).

–	Slightly take up weight of engine/gearbox assembly on engine support bracket -10-222 A-.

–	Remove noise insulation → General body repairs, exterior; Rep. gr.66.

–	Remove front left wheel housing liner → General body repairs, exterior; Rep. gr.66.

Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, Golf SV 2015 ►, vehicles with petrol engine

–	Disconnect connector -1- from oil level and oil temperature sender -G266-.

–	Remove subframe without steering rack → Running gear, axles, steering; Rep. gr.40.

–	Disconnect both drive shafts from gearbox → Running gear, axles, steering; Rep. gr.40.

Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, Golf SV 2015 ►, vehicles with petrol engine

–	Secure drive shaft to suspension strut with tensioning strap -T10038-.

The surface protection of the shafts must not be damaged.

Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, Golf SV 2015 ►, vehicles with petrol engine

Remove all bolts -1- and -2- for gearbox bracket.

Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, Golf SV 2015 ►, vehicles with petrol engine

–	Lower engine/gearbox assembly using spindle -10 - 222 A /11- until distance -a- is obtained between gearbox housing and gearbox mounting.

Dimension -a- = 50 mm

–	Remove gearbox bracket.

–	Remove all connecting bolts except one which is in an easily accessible place between engine and gearbox.

–	Set up gearbox support -3282- with adjustment plate -3282/59-.

Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, Golf SV 2015 ►, vehicles with petrol engine

–	Position engine and gearbox jack -VAS 6931- or -V.A.G 1383 A- under gearbox and support gearbox. Do not raise.

–	Position plate of pin under gearbox housing, not under mechatronic unit.

–	Screw a pin into »rear« hole for pendulum support.

–	Secure gearbox with tensioning strap -T10038- to prevent it from falling down.

The gearbox is separated from the engine in this position.

–	Remove last engine/gearbox connecting bolt.

–	Separate gearbox from engine, »observing selector lever cable«. Slightly tilt gearbox using outer spindle of gearbox support -3282-.

Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, Golf SV 2015 ►, vehicles with petrol engine

–	Now slightly turn gearbox and lower it. Be sure to guide flange -1- past intermediate plate -arrow- when lowering gearbox.

Note

Be careful of all lines when lowering gearbox.

Transporting gearbox → Chapter.

Secure gearbox to assembly stand → Chapter.

Installing gearbox → Chapter.

Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, Golf SV 2015 ►, vehicles with petrol engine

Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, vehicles with diesel engine

Brief description

The gearbox is removed downwards separately.

»From above«

Remove battery, air filter and starter. The engine and gearbox must be supported before the left subframe mounting is removed.

»From below«:

Remove -subframe- together with -pendulum support- and -both suspension links-. The -steering rack- remains installed in the vehicle.

Both drive shafts are disconnected from gearbox and left installed in wheel bearing housings. They are only swivelled to one side and left on vehicle.

Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, vehicles with diesel engine

Special tools and workshop equipment required

Support bracket -10-222A-

Shackle -10 - 222 A /12-

Support bracket -10 - 222 A /31-

Engine support basic set -T40091-

Engine support supplement set -T40093-

Gearbox support -3282-

Adjustment plate -3282/59-

Adjustment plate -3282/59

Tensioning strap -T10038-

Tensioning strap -T10038

Insert tool, 18 mm -T10179-

Insert tool, 18 mm -T10179

Removal lever -80 - 200-

Removal lever -80 - 200

Adapter -T40093/3-6-, qty. 2

or Adapter -T40093/3-6A-

Not illustrated: engine and gearbox jack -VAS 6931- or -V.A.G 1383 A-

Adapter -T40093/3-6

Check adapter -T40093/3-6- and adjust as necessary

–	If necessary, cut off the marked area.

–	Round off the front edges.

–	Protect adapter against corrosion.

–	Then, mark adapter -T40093/3-6- with -T40093/3-6A-.

At a later point, support bracket -10-222 A- will be put onto longitudinal members with adapters -T40093/3-6A-.

To prevent damage to longitudinal member, cover front area of adapter -T40093/3-6A- with textile-reinforced adhesive tape → Electronic Parts Catalogue (ETKA chemical substances).

Removing

–	Raise vehicle. All 4 supports of lifting platform must be at same height.

–	Move selector lever to position »P«.

–	Remove engine cover panel → Rep. gr.10.

–	Remove air filter housing → Rep. gr.23.

–	Remove battery and battery tray → Electrical system; Rep. gr.27.

Adapter -T40093/3-6

–	Using removal lever -80 - 200-, lever selector lever cable -1- off gearbox selector lever.

–	Remove bolts -2-, raise and tie selector lever cable together with support bracket.

Caution

Risk of damage to selector lever cable.

Do not bend or kink selector lever cable.

–	Remove starter → Electrical system; Rep. gr.27.

It is advisable to remove the »lower« bolt first.

Caution

Risk of damaging gearbox components beyond repair.

Do not under any circumstances touch the contacts in the gearbox connector by hand. Electrostatic discharge can seriously damage the control unit and mechatronic unit.

–	Touch earth connection (without gloves) in order to discharge yourself.

Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, vehicles with diesel engine

–	Disconnect electrical connector -1- for mechatronic unit for dual clutch gearbox -J743-. To do this, pull locking mechanism upwards -arrow-.

–	Unscrew nuts -2- and -3- and remove wiring retainer.

–	Tie up wiring in area of gearbox cover.

–	Remove air pipe → Rep. gr.21.

Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, vehicles with diesel engine

–	Unscrew upper engine/gearbox connecting bolt using insert tool 18 mm -T10179-.

–	Remove noise insulation → General body repairs, exterior; Rep. gr.66.

–	Remove lower part of front left wheel housing liner → General body repairs, exterior; Rep. gr.66.

Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, vehicles with diesel engine

–	Disconnect connector -1- from oil level and oil temperature sender -G266-.

–	Remove subframe without steering rack → Running gear, axles, steering; Rep. gr.40.

–	Disconnect both drive shafts from gearbox → Running gear, axles, steering; Rep. gr.40.

Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, vehicles with diesel engine

–	Secure drive shaft to suspension strut with tensioning strap -T10038-.

The surface protection of the shafts must not be damaged.

–	Remove windscreen wiper arms → Electrical system; Rep. gr.92.

–	Remove plenum chamber cover → General body repairs, exterior; Rep. gr.50.

–	If there are hose and cable connections in area of engine support eye for support bracket -10-222A-, remove these now.

–	Install support bracket -10-222 A- as follows:

Required material:

Adapter -10 - 222 A /31-1-

Adapter -10 - 222 A /31-2-

Connecting piece -T40091/3-, qty. 2

Square tube -T40091/1-, qty. 2

Spindle from engine support supplement set -T40093 /3-

Adapter -T40093/3-6- or adapter -T40093/3-6A--A-

–	Remove caps on threaded connections for front suspension struts.

Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, vehicles with diesel engine

–	Fit adapter -10 - 222 A /31-1- and adapter -10 - 222 A /31-2--A- onto suspension strut mountings.

The webs -arrow- must face towards front end.

Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, vehicles with diesel engine

–	Slide connecting piece -T40091/3- onto support bracket -10-222 A-.

–	Bolt support bracket -10-222 A- to adapter -10 - 222 A /31-1- and to adapter -10 - 222 A /31-2-.

-A- = adapters -T40093/3-6A- (⇒ next fig.).

On the right in direction of travel:

–	Remove fuel filter and lay to side. Do not open pipe/hose system → Rep. gr.20.

Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, vehicles with diesel engine

–	If present, pull off wires in front area of web of longitudinal member -arrow-. Do not disconnect pipe/hose system.

–	Place adapter -T40093/3-6A- onto right longitudinal member.

–	If necessary, carefully unclip any pipes for air conditioning system in front area. Do not disconnect pipe/hose system → Heating, air conditioning; Rep. gr.87.

The adapter-T40093/3-6- is locked with the pins -A- behind the web of the longitudinal member -arrow-.

On the left in direction of travel:

Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, vehicles with diesel engine

–	Position adapter -T40093/3-6A- on left longitudinal member directly behind filler pipe for washer fluid reservoir.

The adapter -T40093/3-6A- is locked with the pins -A- behind the web of the longitudinal member -arrow-.

–	Bolt on spindle from engine support supplement set -T40093 /3-, connect it via square tubes -T40091/1- to engine support bracket -10-222 A- and fasten the connection (⇒ previous fig.).

The square tube -T40091/1- must be flush with the connecting piece -T40091/3- and the engine support supplement set -T40093 /3- (⇒ previous illustration).

–	Then attach spindles to engine support eyes.

–	Take up weight of engine/gearbox assembly and support bracket on spindles.

Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, vehicles with diesel engine

Remove all bolts -1- and -2- for gearbox bracket.

Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, vehicles with diesel engine

–	Lower engine/gearbox assembly using spindle -10 - 222 A /11- until distance -a- is obtained between gearbox housing and gearbox mounting.

Dimension -a- = 50 mm

–	Remove gearbox bracket.

Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, vehicles with diesel engine

–	Remove engine/gearbox connecting bolts -1- and -2-.

Note

Loosen engine/gearbox connecting bolt -3- and leave it installed just hand-tight.

–	Set up gearbox support -3282- with adjustment plate -3282/59-.

Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, vehicles with diesel engine

–	Position engine and gearbox jack -VAS 6931- or -V.A.G 1383 A- under gearbox and support gearbox. Do not raise.

–	Position plate of pin under gearbox housing, not under mechatronic unit.

–	Screw a pin into »rear« hole for pendulum support.

–	Secure gearbox with tensioning strap -T10038- to prevent it from falling down.

The gearbox is separated from the engine in this position.

–	Remove last engine/gearbox connecting bolt.

–	Separate gearbox from engine, »observing selector lever cable«. Slightly tilt gearbox using outer spindle of gearbox support -3282-.

Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, vehicles with diesel engine

–	Now slightly turn gearbox and lower it. Be sure to guide flange -1- past intermediate plate -arrow- when lowering gearbox.

Note

Be careful of all lines when lowering gearbox.

Transporting gearbox → Chapter.

Secure gearbox to assembly stand → Chapter.

Installing gearbox → Chapter.

Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, vehicles with diesel engine

Removing and installing gearbox

...

Installing gearbox

Install in reverse order of removal, observing the following: Note Renew bolts which are tightened by turning through a sp ...

Other materials:

Exploded view - mechatronic unit
1 - Bolt For securing mechatronic unit for dual clutch gearbox -J743- on gearbox housing. Qty 3, M8 x 35 Always renew after removing. Specified torque and tightening sequence → Fig. ...

Removing and installing air distribution flap control motor -V428-, RHD vehicles
Special tools and workshop equipment required Vehicle diagnostic tester First carry out the following work: – Switch off all electrical consumers. – ...

Vehicle lifting points
Fig. 205 Lifting point at front for the lifting platform or vehicle jack Fig. 206 Lifting points at rear for the lifting platform or vehicle jack First read and observe the introductory information and safety warnings The vehicle may only be lifted at the points shown in the illustrati ...