K0058963020-Automatic Gearbox 09D Volkswagen R GMBH

Service
Workshop Manual
Touareg 2003 ➤
Automatic gearbox 09D Volkswagen R GmbH
Engine ID
CBW
A
Edition 06.2010
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Service Department. Technical Information

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00 - Technical data
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32 - Torque converter
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37 - Controls, housing
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38 - Gears, control
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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.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2012 Volkswagen AG, Wolfsburg K0058963020

. Volkswagen AG Touareg 2003 ➤
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Automatic
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00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.1 Suggestions and criticism of this workshop manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.2 Information about 6-speed automatic gearbox 09D, general repair notes . . . . . . . . . . . . . . 2
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1.3 hole
Brief overview - driveline guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
spec
es, in part or in w
1.4 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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1.5 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.6 Seals and sealing rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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1.7 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.8 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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1.9 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.10 Guided fault finding, vehicle self-diagnosis and testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
nform
ercia
2 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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3 Identification codes, engine allocation, Touareg 2003 ► . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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4 Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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32 - Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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1 Proper handling and installation of torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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1.1 Checking torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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1.2 Removing and installing torque converter oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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1.3 Draining torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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1.4 Installing torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
37 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1 Connecting »tester« . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1 Connecting vehicle diagnosis, testing and information system VAS 5051 . . . . . . . . . . . . 13
2 Repairing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2 Dismantling and assembling selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4 Checking and adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.5 Removing and installing selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.6 Removing and installing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.7 Signal magnet for Tiptronic switch F189 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.8 Removing and installing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.9 Releasing selector lever without electrical current (emergency release) . . . . . . . . . . . . . . 26
2.10 Removing and installing selector lever position P solenoid N380 . . . . . . . . . . . . . . . . . . . . 27
2.11 Removing and installing selector lever lock solenoid N110 . . . . . . . . . . . . . . . . . . . . . . . . 28
2.12 Removing and installing selector lever locked in position P switch F319 . . . . . . . . . . . . . . 29
2.13 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3 Renewing needle bearing for starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.1 Renewing needle bearing for starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.1 Removing and installing gearbox, vehicles with V10 TDI engine . . . . . . . . . . . . . . . . . . . . 36
4.2 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5 Checking ATF level and topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.1 Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.2 Checking ATF level and topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6 ATF lines and ATF cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.1 Assembly overview - ATF lines, vehicles with V10 TDI engine . . . . . . . . . . . . . . . . . . . . . . 46
6.2 Removing and installing ATF lines and ATF cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.3 Cleaning ATF lines and ATF cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Contents i
Touareg 2003 ➤
Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010
6.4 Bleeding ATF system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

7 Control unit for automatic gearbox J217 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7.1 Removing and installing automatic gearbox control unit J217 . . . . . . . . . . . . . . . . . . . . . . 51
8 Renew seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8.1 Renewing output shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8.2 Renewing oil seals for selector shaftgen. A.G. ..V.ol.ks. w. a.g.en. A. G. .d . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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38 - Gears, control . . . . . . . . r.ise.d. . . . . . . . . . . . . . . . . . . . . . . u.ar.an.t . . . . . . . . . . . . . . . . 57
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1 Removing and installing aut oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . o.r a. . . . . . . . . . . . . . . . .
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1.1 Removing . . . . . .s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
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1.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
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1.3 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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2 Removing and installing ATF strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
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2.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
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2.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
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2.3 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
es, in part or in w
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3 Overview - removing and installing valve body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.1 Removing and installing valve body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.2 Removing and installing gearbox output speed sender G195 . . . . . . . . . . . . . . . . . . . . . . 63
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4 Removing, installing and adjusting multifunction switch F125 . . . . . . . . . . . . . . . . . . . . . . 64
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4.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.2 Installing and adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
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ii Contents
Touareg 2003 ➤
00 – Technical data
1 General repair notes
1.1 Suggestions and criticism of this workshop manual

This workshop manual
This workshop manual was made for you. It should support you
and be an aid to you. If you use ⇒ ELSA, you can send us sug‐
gestions, »praise and criticism« from anywhere in the world.
– One can do this by clicking the ⇒ Feedback button
-at the top in the menu bar-.
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You will not always receive a reply from Volkswagen but your
message will always be read. We make great effort to implement
your suggestions for the workshop manuals. But to do so, we
need your comments.
One example of a reader's suggestion which has been »imple‐
mented« is the chapter „Definitions“ in the workshop manual ⇒
1. General repair notes 1

Touareg 2003 ➤
Automatic gearbox 001; Rep. gr. 39 ; Final drive, differential; Ad‐

justing final drive; Definitions for the Polo 2002.
– Go ahead and »Click« click the link! Have a look.
If you find this chapter useful, or would like such a chapter in this
workshop manual or have additional suggestion, write to us.
So once more:
We make great effort to implement your suggestions for the work‐
shop manuals. But to do so, we need your comments. If we don't
know what is bothering you, we can't improve it.
– Use the ⇒ Feedback button -at the top in the menu bar-.
1.2 Information about 6-speed automatic

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programme No. 300 ; 6-speed automatic gearbox 09D .
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1.3 Brief overview - driveline guide
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1 - Transfer box
❑ ⇒ Rep. gr. 34 ; Remov‐
ing and installing trans‐
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ing and installing trans‐
fer box; Transporting
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transfer box
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2 - Propshafts
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3 - Rear final drive

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4 - Front final drive
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2 Rep. gr.00 - Technical data

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1.4 Tools
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A summary of the special tools and workshop equipment used in
es, in part or in w
the workshop manual precedes each repair procedure and can
t to the co
be found in „Special tools/Workshop equipment“ binder.
The catalogue is also available on ⇒ CD-ROM and can be ordered
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the usual way from Bertelsmann.
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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.
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1.5 Gearbox
♦ If gearbox covers have been unbolted or gearbox has no fluid,
do not run engine or tow vehicle.
♦ First thoroughly clean connecting points and surrounding
areas and then loosen bolts.
♦ When installing the gearbox, ensure that dowel sleeves be‐
tween the engine and gearbox are correctly located.
♦ Place removed parts on a clean surface. Cover parts to pre‐
vent soiling. Use plastic sheeting and paper. Use lint-free
cloths only!
♦ If repair work cannot be performed immediately, carefully cov‐
er or seal components.
♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing.
♦ Do not run engine or tow vehicle with pan removed or when
there is no ATF in gearbox.
♦ With gearbox removed, secure torque converter against falling
out.
♦ After installing, check ATF level ⇒ page 42 .

Touareg 2003 ➤
1.6 Seals and sealing rings

♦ Always renew O-rings, seals and gaskets.
♦ When seals have been removed, check contact surface on
housings or shafts for burrs and damage and rectify as nec‐
essary.
♦ Before installing seals, moisten outer circumference of seal
and sealing lip with ATF depending on installation location.
♦ Only use ATF for automatic transmission components. Other
lubricants cause faults to occur in the gearbox hydraulics.
♦ Open side of oil seal faces oil. n AG. Volkswagen AG do
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♦ After installing, check ATF level ⇒ page d by V 42 . ua
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Be careful when working with oil. Dispose of drained oil ac‐
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cording to regulations. Remember: one drop of oil will contam‐
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inate 1,000 litres of water.
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Do not mix any additives into the oil or use a substitute oil.
Oil which has been drained out cannot be filled again.
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The ATF is obtainable as a spare part.
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Container size 1.0 l - Part No. -G 055 025 A2-
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Capacity ⇒ page 8 .
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1.8 Nuts and bolts
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♦ Loosen and tighten securing bolts and nuts for covers and
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♦ Torque settings are specified for unoiled bolts and nuts.

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♦ Threads of bolts secured with locking fluid must be cleaned
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♦ Use a thread chaser to clear residual locking fluid from all
threaded holes into which self-locking bolts are to be screwed.
Otherwise there is a danger of bolts shearing when subse‐
quently being removed.
♦ Always renew self-locking bolts and nuts.
♦ Torque settings are specified for unoiled bolts and nuts.
1.9 Electrical components

You have probably at some time received an electrical shock
when touching a metal object. This is due to the electrostatic
charge of the human body. This charge can disturb the function
of electrical components of the gearbox and of the selector mech‐
anism.

Touareg 2003 ➤
Note
Before beginning work on electrical components, touch an earth‐

ed object, for example a water pipe or lifting platform. Please do
not touch connectors directly.
1.10 Guided fault finding, vehicle self-diag‐G. Volkswage

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Before making repairs to the gearbox, determine ris the cause of the
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fault as precisely as possible with the aid ofau„guided fault finding“. or
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Carry out Guided fault finding using the vehicle diagnosis,
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testing and information system -VAS 5051- .
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Touareg 2003 ➤
2 Gearbox identification
The 6-speed automatic gearbox 09D is installed in the Touareg.
Allocation ⇒ page 7 .
The gearbox code appears on the type plate to the left on the
bottom of the gearbox.
Example:
1 - Identification code
2 - Automatic gearbox 09D
The gearbox code also ap‐
pears on the vehicle identifica‐
tion plates.
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6
Prote AG.
Rep. gr.00 - Technical data
Touareg 2003 ➤
3 Identification codes, engine alloca‐

tion, Touareg 2003 ►
If parts are required for repair work, it is essential that reference
is made to the gearbox code of the automatic gearbox.
„6-speed 09D four-wheel drive automatic gearbox“
Identification code JXW
Engine 5.0 l - 258 kW
V10 TDI
AG. Volkswagen AG d
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urposes, in part or in wh
t to the co
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3. Identification codes, engine allocation, Touareg 2003 ► 7

Touareg 2003 ➤
4 Capacity
General information on Volkswagen oils can be found in ⇒ Elsa‐
Win; Internet (globe); Language; Technical information; Gearbox
oils . AG. Volkswagen AG d
agen oes
olksw not
Capacities Automatic gearbox 09D d by
V gu
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Initial filling of gearbox by about 9 l ut
ho eo
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manufacturer (filled for life) ss a c
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Filling entire system about 12 l
nl
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(gearbox including ATF (filled for life)
itte
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cooling system)
erm
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Lubricant ATF
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The ATF is obtainable as a spare part. hole
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es, in part or in w
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Prote AG.

Touareg 2003 ➤
32 – Torque converter
1 Proper handling and installation of
torque converter
– Always secure torque converter.
An unsecured torque converter may slide out when the gearbox
is tipped.
Therefore, always work with care.
1.1 Checking torque converter

– Check torque converter hub for scoring -arrow-.
The torque converter is welded and must be renewed if damaged.
1.2 Removing and installing torque convert‐

er oil seal
Special tools and workshop equipment
agen required
AG. Volkswagen AG d
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olks t gu
♦ Oil seal extractor levered-VW
by 681-
V
ara
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es, in part or in w
t to the co
rrectness of i
♦ Thrust piece -3295-

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or
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do
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for
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Prote AG.
1. Proper handling and installation of torque converter 9

Touareg 2003 ➤
1.2.1 Removing
– Apply oil seal extractor lever -VW 681- directly behind sealing
lip of oil seal to avoid damaging stop ring.
1.2.2 Installing
– Apply ATF to circumference and sealing lips of oil seal.
Installation position:
Open side of oil seal faces gearbox.
– Using thrust piece -3295- , drive in torque converter oil seal to
stop of thrust piece.
1.3 Draining torque converter

Special tools and workshop equipment required
♦ Oil extraction unit -V.A.G 1358 A-
♦ Oil extraction probe -V.A.G 1358 A/1-

If ATF has become fouled by abraded material or if a major over‐
haul of gearbox is being performed, drain torque converter as
follows:
AG. Volkswagen AG d
agen o
– Extract ATF from torqueolksconverter using oil extractor
w es n -
ot g
yV
V.A.G 1358 A- and
sed probe -V.A.G 1358 A- .
b ua
ran
ri tee
ho
aut or
ac
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nl
pt
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erm
ab
ility
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es, in part or in w
t to the co
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c
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ate
do
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Cop py
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rig ht
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by lksw
10
cted agen
Prote AG.
Rep. gr.32 - Torque converter
Touareg 2003 ➤
1.4 Installing torque converter

– Lubricate torque converter hub and lips of torque converter
seal each with one drop of ATF (and not more).
– Push torque converter into gearbox to stop.
– Now turn the torque converter while gently pressing it towards
the gearbox.
The torque converter can be felt to slip further into the gearbox
when the notch in the torque converter hub slips into the follower
of the pump gear.
When the torque converter is fitted, the outer lip of the oil seal may
become »inverted«.
– Therefore, pull torque converter 5 mm back out of gearbox
again.
AG. Volkswagen AG d
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This will bring the lip into its »proper position«.
l purpos
– Then push torque converter into gearbox to stop.
nform
ercia
The torque converter is properly installed when the gearbox can

be pushed against the engine flange »without force«.
m
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tion in
– If this is not the case, fit the torque converter again. Then check
r
te o
the installation dimension ⇒ page 12 . thi

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Prote AG.
1. Proper handling and installation of torque converter 11

Touareg 2003 ➤
Installation dimension
• The torque converter is correctly installed when the distance
-a- between the contact surfaces at the threaded holes of the
torque converter and the torque converter housing is at least
19 mm.
AG . Volkswagen AG
– Ensure that the torque converter does not slide »forwards«
ksw
agen does
not
l
during the installation of the gearbox. by
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– If this is not the case, check the installation ofut
hthe
or torque con‐ eo
verter as follows: ss
a ra
c
ce
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nl
pt
du
an
Caution itte
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erm
ab
ility
If engine and gearbox are brought together with force because
ot p
wit
the torque converter is improperly fitted, both gearbox and tor‐
, is n
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que converter will be damaged.
hole
spec
es, in part or in w
t to the co
The torque converter is properly installed when the gearbox can
be pushed against the engine flange »without force«.
rrectness of i
Torque setting for drive plate to torque converter ⇒ page 36
l purpos
– After installing gearbox, check ATF level and top up

⇒ page 42 .
nform
mercia
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or
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ate
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Prote AG.
12 Rep. gr.32 - Torque converter

Touareg 2003 ➤
37 – Controls, housing
1 Connecting »tester«
Volkswagen offers various devices such as
♦ Vehicle diagnosis, testing and information system -VAS 5051-
♦ Vehicle diagnosis, testing and information system -VAS
5051B-
♦ Tester -VAS 5051/11A-
♦ Vehicle diagnosis and service information system -VAS 5052-
♦ Diagnostic system -VAS 5053-
The operation of these »devices« is described in the respective
user's manuals.
The following description refers to the vehicle diagnosis, testing
and information system -VAS 5051- ⇒ page 13 .
1.1 Connecting vehicle diagnosis, testing

and information system -VAS 5051-
AG. Volkswagen AG d
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WARNING
t to the co
♦ During a road test, always secure testing and measuring

rrectne
equipment on the back seat.

♦ These devices may be operated only by a passenger dur‐
s
ing a test drive.

s o
cial p
f inform
mer
– Push connector of diagnosis cable -VAS 5051/1- or -

atio
m
VAS 5051/3- onto diagnosis connection.

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Prote AG.
1. Connecting »tester« 13
Touareg 2003 ➤
– Switch on tester -arrow-.

The »tester« is ready for use when it is possible to choose be‐
tween the buttons Guided functions and Guided fault
finding on the »right« of the screen.
Depending on equipment and version of the tester, other func‐

tions may be »displayed« such as:
♦ ElsaWin
♦ Testing
♦ Self-diagnosis
The »tester« is now ready for use.
– Switch on ignition.
– Touch a button on the screen to start the desired function.
AG. Volkswagen AG d
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14 Rep. gr.37 - Controls, housing

Touareg 2003 ➤
2 Repairing selector mechanism
WARNING
Before working on vehicle with engine running, move selector

lever to position „P“ and apply parking brake.
2.1 Checking selector mechanism

The starter must not operate in the selector lever positions „R“,
„D“ or „S“.
On right-hand drive vehicles, the starter must operate in selector
lever positions „P“ and „N“ only when the button in the selector
lever handle is not pressed.
When selector lever is shifted to position „N“ at speeds above 5
km/h, solenoid for selector lever lock must not engage and block
selector lever. Selector lever can be shifted into a driving gear.
When the vehicle is moving at speeds below 5 km/h (almost sta‐
tionary) and the selector lever is shifted to position „N“, the sole‐
noid for selector lever lock should only engage after about 1
second. Selector lever cannot be shifted out of „N“ position until n AG. Volkswagen AG do
brake pedal is depressed. wage es n
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2.1.1 Selector lever in „P“ positiontho
risand ignition
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switched on au ra
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un
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• Brake pedal not depressed:
an
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itte
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Selector lever is locked and cannot be shifted out of „P“ position
erm
ab
ility
when the button is pressed. Solenoid for selector lever lock blocks
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selector lever.
wit
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ole,
• Brake pedal depressed:
spec
Solenoid for selector lever lock releases selector lever. It is pos‐
t to the co
sible to shift into a driving gear. Slowly shift selector lever from
„P“ through to „S“, checking whether selector lever position in
dash panel insert corresponds to selector lever position.
rrectne
2.1.2 Selector lever in „N“ position and ignition ss
switched on
o
cial p
f inform
• Brake pedal not depressed:

mer
atio
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Selector lever is locked and cannot be shifted out of „N“ position

o
n
c
with the push button pressed. Solenoid for selector lever lock
i
or
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blocks selector lever.

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• Brake pedal depressed:

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Solenoid for selector lever lock releases selector lever. It is pos‐
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2.1.3 Selector lever in position „Tiptronic“
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• Shift selector lever into Tiptronic gate.
The illuminated „D“ symbol in the selector mechanism cover must
go out and the „+“ and „-“ symbols must light up.
When the selector lever is shifted into the Tiptronic gate, the se‐
lector lever position display in the dash panel insert must change
from „P R N D S“ to „6 5 4 3 2 1“.
2. Repairing selector mechanism 15

Touareg 2003 ➤
2.1.4 Ignition and light switched on

The respective symbol in the shift mechanism cover lights up.
2.1.5 Selector lever position display

Simultaneous illumination of all selector lever position display
segments indicates that the gearbox is in gearbox emergency
running mode.
– Check and adjust selector lever cable ⇒ page 20 .
2.2 Dismantling and assembling selector mechanism
1 - Selector lever handle

❑ Removing and installing
⇒ page 17
2 - Clip
3 - Insert
4 - Emblem
❑ Self-adhesive
5 - Sleeve
6 - Cover
❑ With selector indicator
⇒ page 23
7 - Printed circuit board
❑ With Tiptronic switch -
F189- agen
AG. Volkswagen AG d
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❑ Removing and installing uth o eo
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⇒ page 25 ss a c
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❑ Note signal magnet for

un
pt
Tiptronic switch -F189-

an
d
itte
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in cover strip
erm
ab
⇒ page 24
ility
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is n
9 - Cable
h re
ole,

spec
⇒ page 29
t to the co
10 - Selector lever lock sole‐

noid -N110-
rrectne

⇒ page 28
ss
11 - Selector lever position P

o
cial p
solenoid -N380-
inform
❑ Removing and installing ⇒ page 26

mer
atio
m
12 - Bolt, 20 Nm
o
n
c
i
or
❑ Qty. 4
thi
te
sd
va
13 - Retainer
i
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pr
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14 - Retainer
t.
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Cop py
15 - Selector mechanism ht. rig
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❑ With selector lever lock solenoid -N110- and selector lever position P solenoid -N380- . co Vo
by lksw
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❑ Releasing selector lever without electrical current (emergency release) ⇒ page 26
Prote AG.

Touareg 2003 ➤
❑ Can be removed upwards.
16 - Bolt
❑ Adjusting ⇒ page 20
17 - Shift unit/cover
❑ Can be removed downwards only.
18 - Securing clip
❑ Always renew
19 - Selector lever cable
❑ Is removed together with selector mechanism ⇒ Item 15 (page 16) .
❑ Adjusting ⇒ page 20
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gen AG does
20 - Securing clip
Vol
ksw
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❑ Always
ris
ed renew
b ara
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21 - Support
au bracket ra
c
ss
❑ For selector lever cable to gearbox
ce
e
nl
pt
du
an
❑ When tightening, make sure not to distort support bracket
itte
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erm
ab
22 - Bolt
ility
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❑ Self-locking
wit
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❑ Always renew
hole
❑ Allocation ⇒ Electronic parts catalogue „ETKA“ spec

es, in part or in w
t to the co
❑ Threaded holes in gearbox for bolts must always be cleaned. (For example with thread chaser)
Torque settings:
rrectness of i
♦ »Bolt M8« 23 Nm
l purpos
♦ »Bolt M6« 10 Nm
nform
ercia
2.3 Removing and installing selector lever

m
at
om
handle
ion
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ate
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Note
um
for
en
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♦ Four recesses -arrow-are located in the handle to secure the
Cop py
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trim insert. These recesses have been modified. When instal‐
yri
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ht
ling handle, observe respective procedure for installation of
cop Vo
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trim insert. cted agen
Prote AG.
♦ Only handles with modified recesses will be supplied as spare

parts. The insert remains unchanged.
I - Handle with old-type recesses

II - Handle with modified recesses
2.3.1 Removing handle
Note
This procedure applies for all handles.
To prevent damage to handle, follow this procedure:

Touareg 2003 ➤
– Lever out insert.
– Pull clip out of handle.

– Pull button past pressure point until it is locked in position.
– Now pull handle off selector lever.
2.3.2 Installing handle
Note
Observe differing procedures when installing

agen
trim
AG. Volksw ageninsert.
AG d oes
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by
If button is inadvertently risepressed
d into handle, hold handle verti‐
ara
nte
cally and use compressed
ut
ho air from below to carefully blow button e or
outward again untilss it can be pulled out over the pressure point by
a ac
hand.
ce
e
nl
pt
du
an
– Refit assembly aid -A- (included with new handle).

itte
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erm
ab
– Push clip in again.

ility
ot p
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Handle with »old-type« recesses

h re
hole
spec
– Push insert onto stop in handle.

es, in part or in w
t to the co
Note
rrectness of i
To ensure insert locking lugs assume correct position in recesses

l purpos
in handle:
– Slide insert approx. 1 mm back and forth in handle by hand.

nform
ercia
Handle with »modified« recesses

m
at
om
ion
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or
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ate
do
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en
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Cop py
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by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
– Insert clip -2-.
AG. Volkswagen AG d
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– I - Push insert into handle to stop, and then slide upwards
nform
ercia
-arrow-.
m
a
com
– II - Fit sleeve onto handle.
tion in
r
te o
Continuation for all handles
thi
s
iva
do
– Move selector lever to position „N“.
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cum
fo
en
ng
t.
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Cop py
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Prote AG.
– I - Guide sleeve carefully through sliding cover and cross-slide

lying underneath.
– When inserting, take care to guide the sleeve very carefully
through cover strip. Pressing in the sleeve without taking care
will break the cover strip.
– II - Push on handle (handle pointing front to rear) to stop, then
turn.
Installation position: Button faces driver.
– III - Now press handle onto selector lever to stop. It must be
felt to engage.
– Remove assembly aid -A-, depress button and pull sleeve up‐
wards.
– Remove backing from adhesive surface and apply sticker

-arrow-.

Touareg 2003 ➤
2.4 Checking and adjusting selector lever

cable
♦ Torque wrench -V.A.G 1331-
♦ Socket -T40031-
2.4.1 Checking
AG. Volkswagen AG d
– Move selector lever to „P“ position. lksw
agen oes
not
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– Remove noise insulation below gearbox. rised ara
nte
tho eo
– Pull selector lever cable -2- off selector shaft
s au lever. ra
c
s
ce
e
– Move selector lever from „P“ to „S“.

nl
pt
du
an
itte
• Selector lever mechanism and selector lever cable must move

y li
erm
ab
freely. If necessary, renew selector lever cable or selector

ility
ot p
mechanism.
wit
, is n
h re
– Move selector lever to „P“ position.

hole
spec
– Move selector shaft lever on gearbox to position „P“. Locking

es, in part or in w
t to the co
lever must engage in parking lock wheel so that both front

wheels are blocked (cannot be turned together in same direc‐
tion).
rrectness of i
• It must be possible to push selector lever cable onto selector

l purpos
shaft lever. Adjust selector lever cable if necessary.

– Carefully press selector lever cable onto selector shaft lever.
nform
ercia
Do not bend selector shaft lever or selector can no longer be

precisely adjusted.
m
at
om
io
– Adjust selector lever cable ⇒ page 20 .

n
c
in t
or
his
ate
2.4.2 Adjusting
do
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Cop py
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Prote AG.

Touareg 2003 ➤
♦ Socket -T40031-
• Selector lever cable is disconnected from selector shaft lever.

– Move selector lever to position „S“.
– Move selector shaft lever on gearbox to position „D“.
– Remove selector lever handle ⇒ page 17 .
– Procedure for disconnecting batteries must strictly be fol‐
lowed.
– With ignition switched off, disconnect battery ⇒ Electrical sys‐
tem; Rep. gr. 27 ; Disconnecting and connecting battery .
– Remove ashtray and remove shift mechanism cover from cen‐
tre console ⇒ General body repairs, interior; Rep. gr. 68 ;
Compartments, covers and trims; Removing and installing
centre console .
– Remove cover from selector mechanism ⇒ page 23 .
– Remove frame from selector mechanism ⇒ page 25 .
– Loosen clamping bolt on selector lever cable approx. one turn.
. Volkswagen AG
gen AG does
– Carefully push selector lever cable onto selector
Vol
ksw shaft lever,
a
not
taking care not to bend selector shaft lever.
ed by Otherwise selector gu
ara
mechanism cannot be precisely adjusted.
tho
ris nte
eo
au ra
– Centre selector lever by gently smoving
s back and forth in posi‐ c
ce
tion „D“ but without leaving position „D“.

e
nl
pt
du
an
itte
– Tighten clamping bolt to 10 Nm with lever in this position.

y li
erm
ab
Socket insert -T40031- can be used.

ility
ot p
wit
Continue installation in reverse order of removal.

, is n
h re
hole
– Install ashtray and selector lever cover in centre console ⇒

spec
General body repairs, interior; Rep. gr. 68 ; Compartments,

es, in part or in w
t to the co
covers and trims; Removing and installing centre console .

– Connect battery.
rrectness of i
– Follow procedure after connecting battery ⇒ Electrical system;

Rep. gr. 27 ; Battery; Disconnecting and connecting battery .
l purpos

nform
ercia
cable
m
at
om
ion
c
in t
or
his
e
Note
at
do
priv
cum
or
If you fasten a string to the cable before removing it, you can use
f
en
ng
t.
the string to thread the cable back in when installing.
yi Co
Cop py
t. rig
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pyri by
Vo
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by c lksw
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Prote AG.

Touareg 2003 ➤
2.5.1 Removing
– Remove selector mechanism ⇒ page 30 .
– Press gaiter -arrow- forwards out of mounting bracket.
To remove selector lever cable, it is sufficient to lower transfer
box. agen
AG. Volkswagen AG d
oes
olksw not
V gu
– Lower transfer box ⇒ Transfer box and final drives; Rep. gr. ed b y ara
nte
34 ; Removing and installing transfer box . thoris
eo
au ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
is n
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ole,
spec
– Remove securing clip -1-.
t to the co
– Pull selector lever cable -2- off selector shaft lever.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
2.5.2 Installing
r
fo
en
ng
t.
yi Co
op
– Install selector lever cable in mounting bracket -1-. C py
t. rig
gh ht
yri by
– Bring entire surface of sleeve -2- in contact with mounting cop Vo
by lksw
bracket. cted agen
Prote AG.
– Install transfer box ⇒ Transfer box and final drives; Rep. gr.
34 ; Removing and installing transfer box .
– Carefully press selector lever cable -2- onto selector shaft lev‐
er. Do not bend selector shaft lever or selector can no longer
be precisely adjusted.
– Renew securing clip -1-.

Touareg 2003 ➤
– Bring entire surface of cuff -arrow- in contact with mounting

bracket. Volkswa AG. gen AG
agen does
– Install selector mechanism ⇒ page
Vol
ksw 30 . not
gu
y
db ara
rise nte
tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
2.6 Removing and installing cover
t to the co
rrectne
2.6.1 Removing
s
s o
cial p
f
– Procedure for disconnecting the battery must strictly be fol‐
inform
lowed.
mer
atio
m

o
n
c
i
or
n thi
te
sd
a
– Remove cover for centre console ⇒ General body repairs,

iv
o
pr
c
interior; Rep. gr. 68 ; Compartments, covers and trims; Re‐
um
r
fo
moving and installing centre console .

en
ng
t.
yi Co
op py
– Pull off connector -1-. t. C rig
gh ht
pyri by
– Carefully pull catches -2- on left and right off frame.
o Vo
by c lksw
cted agen
Prote AG.
2.6.2 Installing
Install in reverse order of removal. During this step, observe the
following:
– Install cover for centre console ⇒ General body repairs, inte‐
rior; Rep. gr. 68 ; Compartments, covers and trims; Removing
and installing centre console .
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
– Install selector lever handle ⇒ page 17 .

Touareg 2003 ➤
AG. Volkswagen AG d
agen
2.7 Signal magnet
by
Vol
ksw for Tiptronic switch
oes
not -
gu
F189- d ara
ise nte
r
ho t e or
au ac
Two signal magnets
ss -A- and -B- are installed in cover strip -1-.
These magnets send signals about the selector lever position to
ce
e
nl
pt
du
the printed circuit board above them.
an
itte
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erm
ab
ility
ot p
Caution
wit
, is n
h re
During installation work, magnet -A- may get stuck on metallic
hole
spec
objects (e.g. tools). In that case, it must be re-inserted in the
es, in part or in w
correct position.
t to the co
The function of the selector mechanism will be disrupted if the
magnet is installed incorrectly or is missing.
rrectness of i
l purpos
– Even when installing a »new« cover strip, check whether mag‐

net -A- is present and is installed correctly ⇒ page 24 .
nform
ercia
Renew the cover strip if the magnet is lost.

m
at
om
ion
c
2.7.1 Checking installation position of the
in t
or
his
te
magnet
a
do
priv
cum
for
– Take magnet -A- out of cover strip, e.g. using a screwdriver.

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Remove magnet from screwdriver and place on integrated

magnet.
When it is put in place, magnet -A- automatically turns to correct
installation position and is attracted by integrated magnet.

Touareg 2003 ➤
– Now mark side -A- of magnet pointing »upwards«, for example

with a felt pen.
– Insert magnet into cover strip -arrow- with marked side »up‐
wards«.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
– After inserting, make sure that retaining olips
ris -arrows- are in
e nte
eo
contact with magnet. auth
ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
2.8 Removing and installing cover
l purpos
nform
ercia
2.8.1 Removing
m
a
com
t
– Remove cover ⇒ page 23 .
ion in
r
te o
– Pull out catches -arrows- on left and right and pull cover off
thi
s
iva
upwards.
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.8.2 Installing
Install in reverse order of removal.
– Install cover ⇒ page 23 .

Touareg 2003 ➤
2.9 Releasing selector lever without electri‐

AG. Volkswagen AG d
agen
cal current (emergency
by Vol
ksw
release) oes
not
gu
ara
ed nte
oris e
th or
au
Note ss
ac
ce
e
nl
pt
du
The selector lever handle and the cover with selector indicator
an
itte
y li
-2- do not need to be removed for this.
erm
ab
ility
ot p
wit
– Remove storage compartment and centre console ⇒ General
, is n
h re
body repairs, interior; Rep. gr. 68 ; Compartments, covers and
hole
spec
trims; Removing and installing centre console .
es, in part or in w
t to the co
– Remove selector mechanism cover ⇒ General body repairs,
rrectness of i
Selector lever position P solenoid -N380- -1- is on right side in
l purpos
vehicle driving direction -arrow-.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Use a »long, thin« screwdriver to press solenoid core in

-direction of arrow- from above.

Touareg 2003 ➤
– Use a »long, thin« screwdriver to press solenoid core in

-direction of arrow- from above.
– Press selector lever button and move selector lever to position
„N“.

position P solenoid -N380-
AG. Volkswagen AG d
agen oes
2.10.1 Removing byV
olksw not
gu
ara
ed
is nte
– Remove selector mechanismuth⇒ page 30 .
or eo
a ra
s c
– Release connector and pull off. s
ce
e
nl
pt
du
– Release solenoid from retainer and pull it out upwards from

an
itte
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locking lever -1- and selector mechanism.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
2.10.2 Installing
m
at
om
– Position lever of solenoid -2- straight up.

on
c
in t
or
– Insert solenoid at a slight angle into retainer of selector mech‐

his
ate
anism.
do
priv
cum
or
– Connect lever -2- to locking lever -1-.

f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
– Push solenoid into selector mechanism to stop until it engages

in its retainer -arrow-.
– Check that solenoid is located completely in retainer -arrow-
to stop and lever engages-2- in locking lever -1-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
2.11 Removing and installing selector lever ho eo
aut ra
s c
lock solenoid -N110- s
ce
e
nl
pt
du
an
itte
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erm
ab
2.11.1 Removing
ility
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, is n
– Remove selector mechanism ⇒ page 30 .
h re
hole
spec
– Release connector and pull off.
es, in part or in w
t to the co
– Release solenoid from retainer and pull it out straight from
locking lever -1- and selector mechanism.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
yi
2.11.2 Installing
Co
Cop py
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– Position lever of solenoid -2- straight up. op Vo
by c lksw
cted agen
Prote
– Push solenoid into retainer of selector mechanism from in
AG.
front.
– Connect lever -2- to locking lever -1-.

Touareg 2003 ➤
– Push solenoid into selector mechanism to stop until it engages

in its retainer -arrow-.
– Check that solenoid is located completely in retainer -arrow-
to stop and lever engages in locking lever.

locked in position P switch -F319-
The Tiptronic switch -F189- is integrated in the wiring harness for
the two solenoids.
♦ Torque wrench -V.A.G 1783- AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
2.12.1 Removing
rrectness of i

l purpos

lowed.
nf
ercia

rm

m
atio
om
n in
c
– Remove cover for centre console ⇒ General body repairs,

or
thi

te
sd
a

iv
o
r
rp
cu
o
m
f
– Remove bolts -arrows- from centre console.

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
– Release connector -1- and pull off.

– Remove bolt -2- and remove
wage retainer.
n AG. Volkswagen AG do
es ks not
Vol gu
– Pull connector e-3-
d b out of retainer.
y ara
nte
is
or eo
– Pull connectors
au
th of solenoids. ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
– Push securing lever to right and pull switch forwards and up‐
t to the co
wards out of selector mechanism.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
g
2.12.2 Installing
n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
following:
co Vo
by lksw
cted agen
Prote AG.
– Route wires -1- through -3- as shown in figure.
1 - Wiring harness to selector lever lock solenoid -N110-
2 - Wiring harness to selector lever position P solenoid -N380-
3 - Wiring harness to selector lever locked in position P switch -
F319-
– Insert connector -3- in retainer.

– Tighten bolt -2-.
– Push on connector -1-.
– Install cover for centre console ⇒ General body repairs, inte‐
rior; Rep. gr. 68 ; Compartments, covers and trims; Removing
and installing centre console .
2.13 Removing and installing selector mech‐

anism

Touareg 2003 ➤
♦ Socket -T40031-
2.13.1 Removing lksw

agen
AG. Volkswagen AG d
oes
not
Vo gu
y
– Remove selector lever handle ⇒ page 17 ise .
d b ara
nte
or eo
th
– Lift pull rod and move selector lever
s a to position „S“.
u ra
c
s
ce
le
un
pt
lowed.
an
d
itte
y li
erm
– With ignition switched off, disconnect battery ⇒ Electrical sys‐ ab

ility
ot p
tem; Rep. gr. 27 ; Disconnecting and connecting battery . wit

is n
h re
– Remove centre console ⇒ General body repairs, interior; Rep.
ole,
gr. 68 ; Compartments, covers and trims; Removing and in‐

spec
stalling centre console .

t to the co
– Pull noise insulation out of centre console.

– Release connector -1- and pull off.
rrectne
– Remove bolt -2- and remove retainer.

ss
– Pull connector -3- out of retainer.

o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
– Pull off connector -1-.

– Carefully pull catches -2- on left and right off frame.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
– Pull out catches -arrows- on left and right and pull cover off
ce
e
nl
pt
du
upwards.
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove clamping bolt on selector lever cable using socket
nform
ercia
and key -T40031- .

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove bolts -1- and remove front bracket -1- for selector
mechanism.
– Remove rear bracket for selector mechanism.
– Pull selector mechanism with selector lever cable slightly
back.

Touareg 2003 ➤
wage es
– Remove securing clip olksfrom selector lever cable -1-
V-2-
not and pull
gu
by
selector mechanism
ris
e off selector lever cable.
d ara
nt ee
tho or
s au ac
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
2.13.2 Installing
rrectness of i
l purpos
following:
nform
– Attach selector lever cable -1- and secure with new securing
ercia
clip -2-.
m
at
om
io
– Bolt front and rear brackets for selector lever mechanism
n
c
in t
⇒ Item 12 (page 16) .
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Route wires -1- through -3- as shown in figure.

1 - Wiring harness to selector lever lock solenoid -N110-
2 - Wiring harness to selector lever position P solenoid -N380-
3 - Wiring harness to Tiptronic switch -F189-
– Insert connector -3- in retainer.

– Tighten bolt -2-.
– Push on connector -1-.
– Adjust selector lever cable ⇒ page 20 .
– Install centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; Compartments, covers and trims; Removing and in‐
stalling centre console .

Touareg 2003 ➤
3 Renewing needle bearing for starter

n AG. Volkswagen AG ge does
swa
Needle bearing is installed in cars with V10 TDIbyengine.
Vol
k not
gu
ara
d
se nte
Allocation ⇒ Electronic parts catalogue „ETKA“
tho
ri eo
au ra
c
• Engine and gearbox removed ⇒ 10-cylinder
ss diesel engine;
ce
le
Rep. gr. 10 ; Removing and installing engine .
un
pt
an
d
itte
y li
• Starter removed ⇒ Electrical system; Rep. gr. 27 ; Removing erm
ab
and installing starter, automatic gearbox
ility
ot p
wit
is n
h re
ole,
Note
spec
t to the co
Engine does not have to be separated from gearbox in order for
bearing to be renewed.
rrectne
⇒ page 35 describes how to renew needle bearing when gear‐
box is removed from engine.
ss o
cial p
f in
Special tools and workshop
form
mer
equipment required
atio
m
♦ Internal puller Kukko 21/2

o
n
c
i
or
n
commercially available
thi
te
sd
va
♦ Counter support Kukko

i
o
pr
cum
r
22/-1 commercially availa‐

fo
en
ng
ble
t.
yi Co
Cop py
♦ Adapter from multipurpose
t. rig
gh ht
yri
tool -VW 771-
p by
o Vo
by c lksw
cted agen
♦ Adapter -VW771/44-
Prote AG.
♦ Centring mandrel -12 - 551-

Touareg 2003 ➤
wage
3.1 Renewing needle bearing for starter
lks es n
o ot g
byV ua
d ran
ir se
Pulling out uneedle
tho roller bearing tee
or
s a ac
A - Adapter from multipurpose tool -VW 771-
s
ce
e
nl
pt
du
B - Adapter -VW771/44-
an
itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Driving in needle bearing
rrectness of i
– Carefully drive needle bearing in to stop.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
3.1.1 Renewing needle bearing for starter
pyri by
Vo
co lksw
by
(gearbox removed)
cted agen
Prote AG.
Pulling out needle roller bearing

A - Adapter from multipurpose tool -VW 771-
Driving in needle bearing
– Carefully drive in needle bearing to stop with centring mandrel
-12 - 551- .
3. Renewing needle bearing for starter 35

Touareg 2003 ➤
. Volkswagen AG
swa
gen AG does
k not
Vol gu
d by ara
e nte
ris
4 Removing and installing gearbox autho eo
ra
c
ss
Removing and installing gearbox, vehicles with V10 TDI engine
ce
e
nl
pt
du
⇒ page 36
an
itte
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erm
ab
4.1 Removing and installing gearbox, vehi‐
ility
ot p
cles with V10 TDI engine
wit
, is n
h re
hole
Brief description
spec
es, in part or in w
t to the co
The automatic gearbox -09D- is removed together with engine,
front final drive and transfer box. The procedure is described in
the engine repair group.
rrectness of i
In all Touareg engine variants, i.e. in the vehicle you are working
on as well, it is advisable to remove »lower engine/gearbox con‐
l purpos
necting bolts« before removing engine and gearbox. If possible,

you should also fit torque converter securing bolts at an early
nform
ercia
stage. This applies both during removal of gearbox and bolting

gearbox to engine.
m
at
om
io
There are two ways to separate the engine and gearbox from one
n
c
in t
or
another on the scissors-type assembly platform -VAS 6131- :
his
ate
do
riv
First variant
p
cum
for
en
g
Automatic gearbox -09D- and transfer box -1- remain bolted to‐
n
t.
yi Co
gether. They can be unbolted from engine together, for example, Cop py
. rig
in order to remove and install the torque converter.
t
gh ht
pyri by
Vo
co lksw
In this case, the front propshaft -2- is only unbolted from the
by
cted agen
Prote
transfer box at the front. In this way, one can separate the engine
AG.
on one side of the scissors-type assembly platform -VAS 6131-

and both gearboxes on the other side of the platform.
Second variant
First remove the transfer box from the platform, followed by the
automatic gearbox. This enables assembly work to be performed
on the automatic gearbox. To do this, first disconnect the front
propshaft at both ends, then unbolt the transfer box -1- and re‐
move it from the platform. Only then unbolt the automatic gearbox
from the engine and remove the gearbox from the platform as well
if necessary.
This »second variant« is described here.

Touareg 2003 ➤
1 - Transfer box
❑ Notes and torque set‐
tings for installing trans‐
fer box and propshaft ⇒
Transfer box and final
drive; Rep. gr. 34 ; Re‐
moving and installing
transfer box .
2 - Front and rear propshafts n AG. Volkswagen AG do
lkswage es n
o ot g
3 - Rear final drive d byV ua
ran
ir se tee
4 - Front final drive autho
or
ac
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4.1.1 Removing
– For all engine variants, it is advisable to remove »lower engine/
gearbox connecting bolts« before removing engine and gear‐
box.
If possible, torque converter securing bolts should also be instal‐
led as early as possible.
– Remove engine with gearbox ⇒ engine; Rep. gr. 10 ; Re‐
moving and installing engine .
Vehicles with V10 TDI engine
– Remove starter cable far enough that the connecting bolt can
be removed ⇒ Electrical system; Rep. gr. 27 ; Starter; Re‐
moving and installing starter .
4. Removing and installing gearbox 37

Touareg 2003 ➤ agen
AG. Volkswagen AG d
oes
ksw not
Automatic gearbox 09D Volkswagen R GmbH - Edition
by V 06.2010
ol
gu
a
ed ran
oris tee
The torque converter securing bolts and the lower engine/gear‐
ut
h or
ac
s a gearbox
box connecting bolts should be installed with engine sand
ce
e
fitted.
nl
pt
du
an
itte
Ensure that at least two assembly platform plates -VAS 6131/1-
y li
erm
ab
are also under oil pan to support the automatic gearbox.
ility
ot p
wit
– Disconnect propshaft between transfer box and front final
, is n
h re
drive at transfer box.
hole
spec
– Counterhold -T10172- can be used to counterhold propshaft.
es, in part or in w
t to the co
rrectness of i
l purpos
– Counterhold -3435- with two bolts up to maximum M10 is also
suitable.
nf
ercia
or: counterhold -T10172-
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Support transfer box with hoist.
– Unbolt transfer box and lay to side ⇒ Transfer box and final
drive; Rep. gr. 34 ; Removing and installing transfer box .
Before separating engine and gearbox from each other, secure
engine from tipping over.
This is described in the following example.
– If no second hoist is available, separate engine from gearbox
and then support engine using suitable means.
– Support gearbox with hoist ⇒ page 41 .
– Separate ATF pipes ⇒ page 46 .
– Remove all engine/gearbox connecting bolts.
– Carefully push gearbox off engine.
– Ensure that torque converter is also pushed off drive plate to‐
gether with gearbox.
4.1.2 Installing
Installation is performed in the reverse order.

Touareg 2003 ➤
– Before installing gearbox, ensure that torque converter seats

correctly in gearbox ⇒ page 11 .
– Check installation dimension -a- ⇒ page 12 .
Caution
If engine and gearbox are brought together with force because

olkswagen AG
the torque converter is improperlywa en AG. Vboth gearbox
gfitted, doand
es n tor‐
ks
que converter will be damaged.
by
Vol ot g
ua
ed ran
ris tee
tho or
au ac
– Therefore, when
ss securing gearbox to engine, check frequently
ce
le
that the torque converter »moves freely« and is not being

un
pt
pinched.
an
d
itte
y li
erm
ab
– Check selector lever cable adjustment and adjust if necessary
ility
ot p
⇒ page 20 .
wit
is n
h re
Following installation, check ATF level and top up if necessary
ole,
spec
⇒ page 42 and check wheel alignment ⇒ Running gear, axles,
steering; Rep. gr. 44 ; Wheel alignment .
t to the co
Torque settings, vehicles with V10 TDI ⇒ page 39 .
rrectne
4.1.3 Torque settings
s
Vehicles with V10 TDI engine
s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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by
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Prote AG.

Touareg 2003 ➤
AG. Volkswagen AG d
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Dowel sleeves -arrows- ss
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e
nl
pt
du
Bolt Installation position accord‐ Nm

an
itte
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ing to „clock“
erm
ab
ility
ot p
M 12 x 140 12 o'clock 80
wit
, is n
M 12 x 180 1 o'clock 80
h re
hole
M 12 x 155 2 o'clock 65
spec
es, in part or in w
3.30 o'clock 65
t to the co
(starter)
M 12 x 85 4 o'clock 80
5 o'clock 80
rrectness of i
7 o'clock 80
l purpos
M12 x 80 8 o'clock 80
with retainer
nf
ercia
M 12 x 140 Half past 8 o'clock 80

or
10 o'clock 80
m
m
atio
m
Drive plate to torque converter 85

o
n in
or c
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te
sd
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Cop py
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40
AG.
Rep. gr.37 - Controls, housing
Touareg 2003 ➤
Automatic
AGgearbox
. Volkswag09D
enA Volkswagen R GmbH - Edition 06.2010
n G do
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Volks ot g
4.2 Transporting gearbox ris
ed
by ua
ran
tee
tho
or
au ac
ss
ce
le
un
pt
equipment required
an
d
itte
y li
♦ Lifting tackle -2024 A-
rm
ab
pe
ility
ot
♦ Shackle -T10059-
wit
, is n
h re
♦ Workshop hoist -
hole
spec
VAS 6100-
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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fo
en
ng
t.
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Cop py
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rig ht
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by lksw
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Prote AG.
– Secure lifting tackle -2024 A- with shackle -T10059- on work‐

shop hoist -VAS 6100- as shown in figure.
Input shaft side:
1st hole of hook rail in position 1 of lifting tackle .
Output shaft side:
1st hole of hook rail in position 8 of lifting tackle .
Shackle
In position 3 on input shaft side of lifting tackle .
WARNING
Use locking pins to secure hooks and locating pins.

Touareg 2003 ➤
5 Checking ATF level and topping up

If the ATF circuit was opened, it must first be bleed
⇒ page 50 .
Only then can the ATF level be checked and toped up as neces‐
sary ⇒ page 43 .
The ATF is obtainable as a spare part.
Special tools and workshop n AG. Volkswagen AG do

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equipment required byV
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♦ Drip tray -V.A.G 1306- tho tee
or
au ac
♦ Torque wrench - ss
ce
le
V.A.G 1331-
un
pt
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d
itte
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♦ Torque wrench -
erm
ab
V.A.G 1332-
ility
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wit
♦ ATF filling unit -V.A.G
is n
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1924-
ole,
spec
♦ ATF filler pipe -V.A.G
t to the co
1924/1-
♦ Vehicle diagnosis, testing
and information system -
rrectne
VAS 5051-
s
♦ Diagnosis cable, 3m with
s o
voltage supply -
cial p
f in
VAS 5051/1- or diagnosis
form
mer
cable, 5m without voltage

atio
supply -VAS 5051/3-
om
n
c
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Cop py
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Prote AG.
ATF filling unit -V.A.G 1924-

If an »older« ATF filling unit -V.A.G 1924- is used, the width of the
filler hook must be reduced to 20 mm. It is the only way to insert
it into the ATF inspection hole. After cutting hook, clean and re‐
move burrs.
5.1 Brief description

ATF level is specified by »integrated« overflow pipe in oil pan.
The ATF level must checked at a certain temperature with the
engine running. The ATF temperature must be read with the ve‐
hicle diagnosis, testing and information system -VAS 5051B- .

AG. Volkswagen AG d
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Touareg
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o eo
Automatic
aut
h
gearbox 09D Volkswagen R GmbH - Edition r a 06.2010
ss c
ce
le
When test temperature is reached, unscrew ATF inspection plug
un
pt
an
d
from oil pan.
itte
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rm
ab
pe
ility
Caution
ot
wit
, is n
h re
hole
An improper ATF level hinders the function of the gearbox.
spec
es, in part or in w
t to the co
5.2 Checking ATF level and topping up
rrectness of i
Test conditions
l purpos
• Gearbox is not in emergency running mode and ATF temper‐

ature is not above approx. 30 °C.
nform
ercia
• Vehicle level.
m
a
• Selector lever in „P“.
com
tion in
r
• All electrical consumers and air conditioner must be switched

te o
thi
s
off.
iva
do
r
rp
cum
– Secure reservoir of ATF filling unit -V.A.G 1924- to vehicle.
fo
en
ng
t.
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– Connect »tester« and continue switching until it is ready for Cop py
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operation ⇒ page 13 .
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rig by
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– Press Guided functions »on right«.
by lksw
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– Then select vehicle, the gearbox and Check ATF level .

– Press → .
– Apply brake.
– Start engine.
– Move selector lever to each position and leave in each position
for 2 seconds. Then move selector lever to„P“.
– Raise vehicle.
– Place drip tray under gearbox.
At the checking temperature of 35 °C:
– Remove ATF inspection plug from oil pan.
5. Checking ATF level and topping up 43

Touareg 2003 ➤
Surplus ATF runs out if ATF level is too high. AG. Volkswagen AG d
agen oes
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ility
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hole
spec
es, in part or in w
t to the co
– Drain ATF until it drips.
– Install ATF inspection plug with new seal and tighten to 70 Nm.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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op
If ATF level is too low, only ATF in filler hole runs out after plug is C py
t. rig
unscrewed.
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– Wait another approx. 30 seconds. If no ATF drips out after this cted agen
Prote AG.
time, add ATF.
Leave engine running.

Topping up ATF
– To do this, fill with ATF using ATF filling unit -V.A.G 1924- until
ATF flows out of inspection hole.

Touareg 2003 ➤
Drain ATF until it drips.

– Install ATF inspection plug with new seal and tighten to 70 Nm.
– This concludes the ATF check.
– Switch off engine.
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ility
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hole
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by
cted agen
Prote AG.
5. Checking ATF level and topping up 45

Touareg 2003 ➤
6 ATF lines and ATF cooler

♦ Assembly overview - vehicles with V10 TDI engine
⇒ page 46
6.1 Assembly overview - ATF lines, vehicles with V10 TDI engine
1 - Hexagon bolt, 25 Nm
❑ Before tightening bolt,
push in line to stop by
hand.
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2- Hexagon bolt, 8 Nm yV
olks ot g
ua
b
ed ran
3- Hexagon bolt,hor 8 Nm
is tee
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4- Hexagonss bolt, 10 Nm
ce
le
❑ Before tightening bolt,

un
pt
an
d
push in line to stop by

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hand.
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ility
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5 - Thermostat
wit
is n
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ole,
a - ATF line
spec
❑ Moisten O-rings with

t to the co
ATF.
b - ATF line rrectne
❑ Moisten O-rings with

ATF.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by
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Prote AG.

AG. Volkswagen AG d
agen oes
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➤ Touareg e o 2003
ra
ss c
ce
le
un
pt
an
d
6.2 Removing and installing ATF lines and
itte
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ab
ATF cooler
ility
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spec
6.2.1 Removing
t to the co
Overview - coolers
1 - Radiator for engine coolant
rrectne
2 - Retaining clips
s
3 - Condenser
s o
cial p
f i
4 - ATF cooler
nform
mer
5 - Cooler for power assisted steering
atio
om
n
c
6 - Lock carrier
i
or
n thi
te
sd
a
– Remove noise insulation beneath engine ⇒ General body re‐

iv
o
pr
c
pairs, exterior; Rep. gr. 50 ; Body; Noise insulation .
um
r
fo
en
ng
t.
– Remove front bumper ⇒ General body repairs, exterior; Rep.
yi Co
op
gr. 63 ; Bumpers; Front bumper .
C py
t. rig
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– Move lock carrier to service position ⇒ General body repairs, cop Vo
by lksw
cted
exterior; Rep. gr. 50 ; Front body; Lock carrier service posi‐
agen
Prote AG.
tion .
– Remove bolt -1- and pull ATF lines out of thermostat -2-.
– Seal ATF lines and thermostat with clean plugs.
– Unbolt ATF lines from and to ATF cooler at thermostat -2-. In
the process, hold against thermostat.
– Seal ATF lines and thermostat with clean plugs.
– Separate securing clips -arrow- for condenser -1- and ATF

cooler -2-.
– Remove ATF cooler with lines.
– Unbolt ATF lines from ATF cooler. In the process, counterhold
on ATF cooler.
– Seal off ATF lines and ATF cooler with clean plugs.
– Remove bolt for ATF line retainer from engine.
6. ATF lines and ATF cooler 47

Touareg 2003 ➤
– Remove bolt for ATF line retainer from gearbox.
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– Remove ATF lines from gearbox.

itte
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ab
pe
– Seal ATF lines and gearbox with clean plugs.
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
6.2.2 Installing
m
a
com
tion in
r
te o
following: thi
s
iva
do
r
– Moisten O-rings with ATF.

rp
cum
fo
en
g
– Remove plugs and push ATF lines into gearbox to stop.

n
t.
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Cop py
– Tighten bolt ⇒ Item 1 (page 46) .
t. rig
gh ht
pyri by
Vo
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cted agen
Prote AG.
– Tighten bolt for ATF line retainer on gearbox

⇒ Item 2 (page 46) .
– Tighten bolt for ATF line retainer on right side of engine
⇒ Item 3 (page 46) .
– Remove plugs and bolt ATF lines to ATF cooler and thermo‐
stat ⇒ Item a (page 46) .

Touareg 2003 ➤
– Install condenser -1- and ATF cooler -2-.

– Insert securing clips -arrow-.
AG. Volkswagen AG d
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– Remove
s au plugs, push ATF lines completely into thermostat ra
c
-2- and tighten bolt -1- ⇒ Item 4 (page 46) .
s
ce
le
un
pt
– Check and top up ATF level ⇒ page 42 .
an
d
itte
y li
rm
ab
– Check ATF lines for leaks when checking ATF level.
pe
ility
ot
wit
– Install lock carrier ⇒ General body repairs; Rep. gr. 50 ; Body,
, is n
h re
front; Lock carrier, service position .
hole
spec
– Install front bumper ⇒ General body repairs, exterior; Rep. gr.
es, in part or in w
t to the co
63 ; Bumpers; Front bumper .
– Install noise insulation beneath engine ⇒ General body re‐
pairs, exterior; Rep. gr. 50 ; Body; Noise insulation .
rrectness of i
l purpos
6.3 Cleaning ATF lines and ATF cooler

nform
ercia
If ATF is dirty or if an exchange gearbox is to be installed, blow

out ATF cooler and ATF pipes with compressed air (not more than
m
10 bar).
com
tion in
r
te o
thi
WARNING
s
iva
do
r
rp
cum
fo
Wear eye protection.

en
ng
t.
yi Co
Cop py
ht. rig
rig ht
by
– Thoroughly clean area around unions for gearbox to ATF line,
copy Vo
by lksw
ATF line to thermostat and ATF line to ATF cooler.
cted agen
Prote AG.
– Remove bolt -1- and pull ATF lines out of thermostat -2-.
– Unbolt ATF lines from and to ATF cooler at thermostat -2-. In
the process, hold against thermostat.
– Remove and drain ATF cooler ⇒ page 47 .
6. ATF lines and ATF cooler 49

Touareg 2003 ➤
– Remove ATF lines from gearbox.

– Push a hose onto one end of the ATF line between gearbox
and thermostat and secure with a hose clip. Hang other end
of hose in a suitable container.
– Blow compressed air through ATF line.
– Push hose onto other ATF line and repeat procedure.
– Moisten O-rings with ATF.
– Install ATF lines and ATF cooler ⇒ page 47 .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
ho eo
6.4 Bleeding ATF system ut ra
s a c
s
ce
le
– First check ATF level and top up as described in ⇒ page 42 .

un
pt
an
d
itte
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erm
ab
WARNING
ility
ot p
wit
is n
h re
Wear eye protection.
ole,
spec
t to the co
– Carry out road test whereby the ATF temperature reaches at
least 100° C so that the ATF system can bleed itself.
rrectne
As air escapes from the ATF system, the ATF level in the gearbox
sinks. Therefore, the ATF level must be checked again after the
ATF has cooled off.
ss o
cial p
f
– Let ATF cool to below 30° C
inform
mer
– Check ATF level again ⇒ page 42 .
atio
om
n
c
i
or
n thi
te
sd
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o
pr
cum
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fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
7 Control unit for automatic gearbox -

J217-
AG. Volkswagen AG d
agen oes
olksw not
V gu
by
7.1 Removing and installing automatic gear‐ d ara
ise nte
or eo
box control unit -J217-
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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rp
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f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
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Prote AG.
7.1.1 Removing
– Before removing control unit for automatic gearbox -J217- ,
first read control unit identification, which includes coding of
control unit used up to now.
Note
♦ To avoid damage to front trim beneath right front seat, catches

for trim are shown in the following figure.
♦ Locking lugs -A- engage behind a cross bar beneath the seat.
Press down trim and push towards back at the same time. Hold
trim in this position and pull upwards in the vicinity of locking
lugs -A- to release them.
♦ Locking lugs -B- engage in notches in a cross member in front
of seat. They must be released by pressing down and pulling
forwards.
♦ Locking lugs -C- are in clipped into side trim of seat and must
be unclipped by pulling forwards.
– Move seat to rear upper position.
7. Control unit for automatic gearbox J217 51

Touareg 2003 ➤
– Release locking lugs „A“ -arrows A- by pressing down and

pushing back at the same time. In this position, raise trim in
vicinity of locking lugs „A“ -arrows A-.
– Press down trim and pull forwards at the same time. This re‐
leases locking lugs „B“ -arrows B- and „C“ -arrows C-.
– Move seat to forward upper position.
– Procedure for disconnecting batteries must strictly be fol‐
lowed.
. Volkswage
tem; Rep. gr. 27 ; Disconnecting and connecting
sw agen AG battery n. AG doe
s
k not
Vol gu
d by ara
e nte
ris
Control unit for automatic gearbox
utho -J217- and transfer box control eo
ra
a
unit -J646- are located in housing
ss -1-. c
ce
le
un
pt
– Release connector from transfer box control unit -J646- -2-
an
d
itte
and connector from control unit for automatic gearbox -J217-
y li
rm
ab
-3- and pull them off.
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove bolt -1- and pull housing with control units out of sup‐
l purpos
port.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Pull locking lugs outwards -arrows 1- and pull control unit out
of housing -arrow 2-.
7.1.2 Installing
following:
– Check coding using until now and code new control unit.
– Install seat trim ⇒ General body repairs, interior; Rep. gr. 72 ;
Front seats; Removing and installing seat .

Touareg 2003 ➤
– Follow procedure after connecting battery ⇒ Electrical system;

Rep. gr. 27 ; Battery; Disconnecting and connecting battery .
AG. Volkswagen AG d
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an
d
itte
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erm
ab
ility
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wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
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Prote AG.
7. Control unit for automatic gearbox J217 53

Touareg 2003 ➤
8 Renew seals
8.1 Renewing output shaft seal

equipment required
♦ Puller -T10055-
♦ Adapter -T10055/2-
♦ Sleeve -T10180-
♦ Thrust piece -T10186-
AG. Volkswagen AG d
agen oes
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aut ra
ss c
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nl
pt
du
an
itte
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erm
ab
ility
ot p
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, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
8.1.1 Removing
p
cum
for
en
ng
t.
yi
– Remove transfer box ⇒ page 36 .
Co
Cop py
ht. rig
– To pull out seal, screw sheet metal screw of about 4 mm di‐
rig ht
py by
o Vo
ameter into seal -arrow-. by c lksw
cted agen
Prote AG.
♦ Screw sheet metal screw in so that it jams between seal and
metal ring.
♦ Do not screw in sheet metal screw too far to avoid damaging
bearing behind it.
– Pull out seal using puller -T10055- .

Touareg 2003 ➤
8.1.2 Installing
– Coat sealing lips of new ring with ATF.
– First put sleeve -T10180- on output shaft to prevent damage

to seal.
– Then drive new oil seal in to stop using thrust piece -T10180- .
Do not cant oil seal in the process.
wage
– Finally, check ATF level and top up ⇒ page 42 . olks es n
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a ac
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ility
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is n
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ole,
spec
t to the co
rrectne
8.2 Renewing oil seals for selector shaft
ss o
cial p
f
inform
mer
♦ Thrust piece -T10174- atio

om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Scriber
– When removing seals, use scriber carefully.
– Apply ATF to circumference and space between sealing lips
of new seals.
Installation position:
Open side of seal faces gearbox.
8. Renew seals 55
Touareg 2003 ➤
– Drive in new seals using thrust piece -T10174- , taking care

not to cant seals.
– Install and adjust multifunction switch ⇒ page 64 .
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ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
38 – Gears, control
1 Removing and installing oil pan
♦ Drip tray -V.A.G 1306-

AG. Volkswagen AG d
agen oes
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d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
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itte
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1.1 Removing
– Remove gearbox noise insulation.
rrectness of i
– Place drip tray -V.A.G 1306- underneath.
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– Remove drain plug -1-.

– Drain ATF. nform
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– Unscrew oil pan bolts -2- in diagonal sequence and remove

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1.2 Installing
– Clean all four magnets in recesses of oil pan. Ensure that
magnets are seated correctly in pan.
1. Removing and installing oil pan 57

Touareg 2003 ➤
– Install oil pan with new gasket -1-.

– Ensure that all spacer sleeves -2- are completely located in
new gasket -1-.
– Tighten pan bolts diagonally in several stages ⇒ page 58 .
Renew seal of drain plug.
– Tighten drain plug ⇒ page 58 .
– After installing, fill up ATF, check ATF level and top up
⇒ page 42 .
1.3 Torque settings

Drain plug 20 Nm
Oil pan bolts 8 Nm
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58 Rep. gr.38 - Gears, control

Touareg 2003 ➤
2 Removing and installing ATF strainer

2.1 Removing
– Remove oil pan ⇒ page 57 .
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2.2 Installing
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Brief description
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ATF strainer is initially only screwed on »loosely«. Then it is cen‐

tred and pushed into valve body.
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Proceed carefully when doing this, to make sure the oil seal is
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– »Loosely« position ATF strainer against valve body but do not
AG.
push it in yet!
– Now screw both bolts -A- approx. 3 turns (no more!) into valve
body.
2. Removing and installing ATF strainer 59

Touareg 2003 ➤
– Screw in bolt -B- half way (approx. 5 turns).

Centre ATF strainer
ATF strainer »can be felt« to centre in seat of valve body.
– Centre ATF strainer and apply even pressure to corners
-arrows- until it reaches stop inside valve body. Hold in this
position!
– Tighten bolts -A- and -B- by hand.

– Tighten ATF strainer ⇒ page 60 .
– Install oil pan ⇒ page 57 .
⇒ page 42 .
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Touareg 2003 ➤
3 Overview - removing and installing

valve body
Valve body and/or lines can be removed and installed both with
gearbox installed and with gearbox removed.
1 - Solenoid valve 2 -N89-

2 - Connector of gearbox out‐
put speed sender -G195-
❑ Sender is located be‐
hind valve body
⇒ page 63
4 - Gearbox input speed send‐
er -G182-
5 - Gearbox oil temperature
sender -G93-
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11 - Solenoid valve
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For more information about how the components function and

about the fault pattern if a part fails, refer to ⇒ Self-study pro‐
nform
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gramme No. 300 ; 6-speed automatic gearbox 09D .

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3.1 Removing and installing valve body

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– Remove oil pan ⇒ page 57 and strainer ⇒ page 59 if this has

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not already been done.

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3. Overview - removing and installing valve body 61

Touareg 2003 ➤
Only gearboxes with hydraulic pressure sender:

– Carefully pull off connectors for hydraulic pressure sender 1
for automatic gearbox -G193- -1- and hydraulic pressure
sender 2 for automatic gearbox -G194- -2-.
Continued for all gearboxes:
– Unscrew connector.
– Carefully release connector and pull off.
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– Tighten gearbox oil temperature sender -G93- to 10 Nm.

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Touareg 2003 ➤
– Remove bolts of valve body diagonally.

Torque setting: 8 Nm + 90°.
– Install in reverse order of removal.
⇒ page 42 .
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– Remove valve body
ss ⇒ page 61 .
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– Unscrew bolt from gearbox output speed sender -G195- .
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– Pull sender out of gearbox.
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– Press sender into gearbox to stop.
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– Tighten gearbox output speed sender -G195- to 10 Nm.

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– Install valve body ⇒ page 61 .

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3. Overview - removing and installing valve body 63

Touareg 2003 ➤
4 Removing, installing and adjusting

multifunction switch -F125-
♦ Setting gauge -T10173-

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4.1 Removing
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For the sake of clarity, this procedure shows an removed gearbox.
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– Move selector lever to „P“ position.

– Remove cap nut -4-. nf
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– Remove cover -3- from selector shaft.

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– Carefully bend back hook of lock washer -1- using a screw‐

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If a hook breaks off, the washer must be renewed.

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– Now remove nut -2- and lock washer -1- from selector shaft.
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4.2 Installing and adjusting

– Move selector shaft lever on gearbox to position „N“.

Touareg 2003 ➤
– Place multifunction switch -F125- on selector shaft.

– Tighten securing bolts -arrows B- for multifunction switch -
F125- by hand.
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– Set setting gauge -T10173- on selector shaft.
nform
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– Disconnect selector lever cable.

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– Turn multifunction switch -A- far enough that lug of connector

-arrow 1-engages in groove of setting gauge -T10173- .
4. Removing, installing and adjusting multifunction switch F125 65

Touareg 2003 ➤
– Tighten securing bolts -arrows- for multifunction switch -F125-

to 6 Nm.
– Now remove setting gauge -T10173- from selector shaft.
– Connect selector lever cable.
Further installation is carried out in the reverse sequence.
– Check selector lever cable adjustment ⇒ page 20 .
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K0058963020-Automatic Gearbox 09D Volkswagen R GMBH

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Service

Service Department. Technical Information

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Copyright © 2012 Volkswagen AG, Wolfsburg K0058963020

1.9 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6.4 Bleeding ATF system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

1.3 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

1.1 Suggestions and criticism of this workshop manual

1. General repair notes 1

Automatic gearbox 001; Rep. gr. 39 ; Final drive, differential; Ad‐

1.2 Information about 6-speed automatic

1.3 Brief overview - driveline guide

❑ ⇒ Rep. gr. 34 ; Remov‐

❑ ⇒ Rep. gr. 39 ; Remov‐

ing and installing prop‐

3 - Rear final drive

2 Rep. gr.00 - Technical data

Uncertainty often occurs with smaller bolts having low tightening

1. General repair notes 3

1.6 Seals and sealing rings

Be careful when working with oil. Dispose of drained oil ac‐

cording to regulations. Remember: one drop of oil will contam‐

Container size 1.0 l - Part No. -G 055 025 A2-

♦ Torque settings are specified for unoiled bolts and nuts.

1.9 Electrical components

4 Rep. gr.00 - Technical data

Before beginning work on electrical components, touch an earth‐

1.10 Guided fault finding, vehicle self-diag‐G. Volkswage

1. General repair notes 5

3 Identification codes, engine alloca‐

3. Identification codes, engine allocation, Touareg 2003 ► 7

8 Rep. gr.00 - Technical data

1.1 Checking torque converter

1.2 Removing and installing torque convert‐

♦ Thrust piece -3295-

1. Proper handling and installation of torque converter 9

1.3 Draining torque converter

♦ Oil extraction probe -V.A.G 1358 A/1-

1.4 Installing torque converter

– Then push torque converter into gearbox to stop.

The torque converter is properly installed when the gearbox can

the installation dimension ⇒ page 12 . thi

1. Proper handling and installation of torque converter 11

– After installing gearbox, check ATF level and top up

12 Rep. gr.32 - Torque converter

1.1 Connecting vehicle diagnosis, testing

♦ During a road test, always secure testing and measuring

equipment on the back seat.

ing a test drive.

– Push connector of diagnosis cable -VAS 5051/1- or -

VAS 5051/3- onto diagnosis connection.

– Switch on tester -arrow-.

Depending on equipment and version of the tester, other func‐

14 Rep. gr.37 - Controls, housing

2 Repairing selector mechanism

Before working on vehicle with engine running, move selector

2.1 Checking selector mechanism

• Brake pedal depressed:

Solenoid for selector lever lock releases selector lever. It is pos‐