7-speed dual clutch gearbox 0AM — Assembling gearbox — VW

🧭 Before you start

Fits: platform code XXX

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• Watch out for both locking collars. Mouth »top« and mouth »bottom«(arrow) must be inserted correctly.
• Make sure that you do not strike bearing against clutch housing.
• Make sure all selector forks and pinion shafts are correctly seated.
• Adhesive bead should seal oil space. Therefore, do not spray around holes.
• Do not grip cleaned flange surfaces when putting on gearbox housing.

📋 Procedure

1. First install outer input shaft.
2. Heat clutch housing in area of outer input shaft to approx. 100 °C using a hot air blower.
3. Remove shaft again, heat clutch housing correctly.
4. After cooling down: tighten 3 bolts.
5. Turn clutch housing around.

6. Drive in outer, »new« oil seal with a plastic mallet until flush with clutch housing.
7. ⚠ Only drive in oil seal until flush, in order to avoid closing off oil drilling located behind it. Otherwise, bearing can no longer be supplied with enough oil. — Turn clutch housing back around.
8. Insert inner input shaft with roller bearing.
9. Shift all locking collars of output shafts 2 and 3 »downwards«.
10. Insert selector fork for 6th gear and reverse gear.
11. Fork cannot be turned in its position unless it is »all the way down«.
12. Insert selector fork for 5th and 7th gears.
13. Insert output shaft 2.
14. Watch out for both locking collars. Mouth »top« and mouth »bottom«(arrow) must be inserted correctly.
15. Output shaft 2 is placed on clutch housing, not in bearing race.
16. Insert output shaft 3.
17. Watch out for mouth of selector fork and locking collar.
18. Install differential.
19. Make sure that you do not strike bearing against clutch housing.
20. Carefully insert output shafts into bearings.
21. Raise inner input shaft slightly. This allows output shaft 2 to find its installation position.
22. Take out guide pin3411.
23. On output shaft 1, shift »upper« locking collar upwards.
24. Insert output shaft 1 »at an angle from above«.
25. First insert selector fork for 2nd and 4th gears into collar then swivel it to its guide.
26. Insert selector fork for 1st - 3rd gears onto collar then swivel it to its guide.
27. Raise inner input shaft slightly. In this way, you can move output shaft 1 into its installation position.
28. After insertion, position all selector forks in neutral.
29. Make sure all selector forks and pinion shafts are correctly seated.
30. Insert magnet.
31. Insert dowel sleeves.
32. Mount support bridge T10323 from below.
33. Turn spindle against inner input shaft until finger-tight.
34. Drip oil onto all exposed tapered roller bearings.
35. Prepare gearbox housing to be put on.
36. Apply a bead of assembly adhesiveAMV 174 003 02 onto flange of clutch housing.
37. Adhesive bead should seal oil space. Therefore, do not spray around holes.
38. Put on gearbox housing. [Note: Do not grip cleaned flange surfaces when putting on gearbox housing.]
39. Make sure that selector forks locate in their sockets.
40. Place large inner diameter of tubeVW 416 B onto inner ring.
41. A second mechanic should hold gearbox housing in position as early as possible »when pressing on«.
42. Apply targeted blows with a plastic hammer to drive inner input shaft into its bearing.
43. Make sure seating on guide bushes is correct.
44. Take a look at joint of retaining ring.
45. Install new retaining ring.
46. Remove support bridge T10323 from below.
47. Screw new connecting bolts against gearbox housing. Do not tighten them yet.
48. A second mechanic turns gearbox whilst housing halves are being tightened.
49. To do this: engage 1st gear.
50. Use hub of clutch for turning.
51. Tighten new connecting bolts.
52. Set gearbox to neutral.
53. Knock cover of "“inner input shaft”" in until flush.
54. Install connecting bolts of housing halves at clutch end.
55. Install drain plug.
56. Install oil seals of input shafts .
57. Install parking lock.
58. Install new bolts.
59. Installing mechatronic unit .
60. Install flange shafts or stub shafts, installing new sealing rings as you do so .

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