Amarok 8 Speed Automatic Gearbox

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00 - Technical data
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30 - Clutch
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32 - Torque converter i ,
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37 - Controls, housing e
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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.
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30 - Clutch
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37 - Controls, housing e
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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.
Amarok 2011
2011 ➤
8-speed automatic
g e n A
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0CM - Edition 04.2013
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1.1 Tools . . . . . . . . t. p. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . y .. . .. .
t i
1
o
w
1.2
1.2 Gear
Gearbo
box x . . . . . s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i
n
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h . . . . .
t 1
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1.3
1.3 Gask
Gasket
etss and
and seal
se l als
e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p s . . . . 2
e
o
h
1.4
1.4 ATF
ATF . . . . . . . w. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c . . . . 2
e
t
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1.5
1.5 Nuts
Nuts and
and bolt
boltss o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .o h . . . 2
t
i
r t
e
1.6
1.6 Elec
Electr
tric
ical
al comp
compon
a
onen
t
r
ents
ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . oc . . . 3
p
1.7
1.7 Cont
Contac
actt cor
corro
rosi
ision on!! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . e. . .
n
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2.1
2.1 Rule
Rules
s for
for safe
safety
ty when
p when work
workin
ing
g on
on the
the gear
r
gearbo
box
x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o. . . s
4
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3.1
3.1 Rule
Rules
s for
for clea
cleanl
nlin
ines
ess
s whe
when
n work
workin
ing
g on the
c
the gear
gearbo
box m
x . . . . . . . . . . . . . . . . . . . . . . . . . . a
r
. .. . 6
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4.1
4.1 Allo
Alloca
cati
tion
on of gear
gearbobox x to engi engine ne,, gea
gearr rati
ratios
r
os . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
o t
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4.2
4.2 Capa
Capaci
citi
ties
es . . . . . . a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . d
. .. .. .. . 7
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1.1
1.1 Asse
Assemb
mblyly over
overvi
view
ew - tor
torqu
que e conv
conver erte 9
e
t o
r
P
1.2
1.2 Prop
Proper
er hand
handliling
ng of torq
torqueue conv
conver
erte
terr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3
1.3 Remo
Removi ving
ng and
and ins
insta
tall
llin
ingg tor
torqu
quee con
convevertrter
er oil
oil sea
seall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4
1.4 Drai
Draini
ning
ng torq
torque
ue conv
convererte
terr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.5
1.5 Remo
Removi ving
ng and
and ins
insta
tall
llin
ingg tor
torqu
quee con
convevertrter
er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.1
1.1 Asse
Assemb
mblyly over
overviview
ew - sel
selec
ecto
torr leve
leverr hand
handle le . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2
1.2 Chec
Checki
king
ng sele
select
ctor
or mech
mechan anis
ism
m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3
1.3 Emer
Emerge
genc
ncyy rel
relea
ease
se from
from posi
positition
on »P«
»P« . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4
1.4 Remo
Removiving
ng and
and ins
insta
tall
llin
ing
g sel
selec
ectotorr lev
lever
er hand
handle le . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.5
1.5 Remo
Removiving
ng and
and inst
instal
alli
ling
ng sele
selectctor
or mech
mechananisism
m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.6
1.6 Chec
Checki
king
ng and
and adj
adjus
usti
ting
ng sele
select
ctor
or leve
leverr cab
cablele . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.7 Removi
Removingng and
and instal
installin
ling
g cable
cable suppor
supportt brac
bracket
ket for select
selector or lever
lever cable
cable . . . . . . . . . . . . . . . . 21
1.8
1.8 Remo
Removiving
ng and
and ins
insta
tall
llin
ing
g gea
gearb
rboxox sele
select
ctor
or leve
leverr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.1
2.1 Remo
Removi
ving
ng and
and ins
insta
tall
llin
ing
g gea
gearbrbox
ox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2
2.2 Rene
Renewi
wing
ng outp
output
ut shaf
shaftt sea
seall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.1 Removi
Removing
ng and
and instal
installin
ling
g gearb
gearbox
ox carrie
carrier/g
r/gea
earb
rbox
ox moun
mountin
ting
g . .. .. .. .. .. .. .. .. .. .. .. . 35
4.1
4.1 Tran
Transp
spor
orti
ting
ng gear
gearbo
box
x . . .. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . . 37
5.1
5.1 Asse
Assemb
mbly
ly over
overvi
view
ew - ATF
ATF circ
circuiuitt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.2
5.2 Remo
Removi
ving
ng and
and ins
insta
tall
llin
ing
g ATF
ATF cool
cooler er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.3
5.3 Remo
Removi
ving
ng and
and inst
instal
alli
ling
ng ATF
ATF line
lines,s, ATF
ATF coolcoolerer/t
/the
hermrmosostatatt . . . . . . . . . . . . . . . . . . . . . . . . 42
5.4
5.4 Remo
Removi
ving
ng and
and inst
instal
alli
ling
ng ATF
ATF line
lines,s, ther
thermomost stat
at/g
/gea
earbrbox
ox . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.5
5.5 Remo
Removi
ving
ng and
and ins
insta
tall
llin
ing
g ATF
ATF filt
filter
er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.6
5.6 Clea
Cleani
ning
ng ATF
ATF cir
circu
cuit
it . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
i
Amarok 2011 ➤
8-speed automatic gearbox 0CM - Edition 04.2013
6.1 Checking ATF level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

6.2 Draining and filling ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.1 Assembly overview - sump/oil strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

1.2 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.3 Removing and installing hydraulic impulse oil storage with accumulator solenoid N485 . . 60
2.1 Removing and installing mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
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ii
Amarok 2011 ➤
(VRL005441; Edition 04.2013)
A summary of the special tools and workshop equipment used in

the workshop manual precedes each repair procedure and can
be found in “Special tools/Workshop equipment” binder.
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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♦ If gearbox e covers have been unbolted or gearbox has no fluid,
i
,
r
e
l
do not run h
oengine or tow vehicle either.
s
p
e
w
c
♦ First thoroughly clean connecting points and surrounding

t
n
i
t
o
r
areas and o

then loosen bolts.
t
h
t
e
r
c
a o
p
♦ When installing
i the gearbox, ensure that dowel sleeves be‐
n
r
e
r
tween the , engine and gearbox are correctly located.

s
c
t
n
e
s e
o s
♦ Place removed
p parts on a clean surface. Cover parts to pre‐
r o
s
vent soiling. p Use plastic sheeting and paper. Use lint-free

u
n
f
i
cloths only!
l
a i
f
o
r
c
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e
a
♦ If repair work
mcannot be performed immediately, carefully cov‐ t
i
o
m
er or seal components.
o
c
n
i
n
r
o t
h
♦ Install only clean
t parts; do not remove new parts from pack‐
e
a
i
s
d
o
aging until immediately
v
i
r before installing. c
u
p r m
o
f e
♦ Do not run engine g
or tow vehicle with pan removed or when n
t
.
C
n
i
there is no ATF in gearbox.
y
p
o o
p
C
.
t r y
i
h
♦ With gearbox removed, secure torque converter against falling V y b g g
i
r
y
h
t
p
out. l o
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b
d a
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A
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♦ After installing, check ATF level ⇒ page 51 .
1
Amarok 2011 ➤
. Volksw age n AG
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♦ Renew O-ring, seals and gaskets. V o o t
b y g u
e d
a r
a n
r i s t
♦ When seals have been removed, h
t
o check contact surface on e
e
u o
housings or shafts for burrs s
a and damage and rectify as nec‐ r
a
c
s c
essary. n
e
l e
p
u t
a
d n
e
♦ Before installing the iseal, slightly moisten outer circumference t
t
y
l
i
m
a
of seal and sealing r
e lip with ATF depending on installation lo‐
b
i
l
i
p
cation.
t
t
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♦ Only use ATF for e
automatic transmission components. Other
i
,
r
e
l
lubricants cause faults to occur in the gearbox hydraulics.
s
o p
h e
w
c
♦ Open side of noil seal faces oil.

t
t
i o
r
o
t
h
e
♦ After installing, check ATF level ⇒ page 51 .
t
r
c
a o
p r
r
n
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c
s t
e n
s e
o s
p s
r o
u f
p
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a
i
f
o
c
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a
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Do not mix any additives o
into the ATF oil or use a substitute oil.
f
r
e
g n
t
.
C
n
i
Drained ATF oil must not be y
reused.
p
o o
p
C
.
t r y
i
Use only ATF available from the ⇒ Electronic Parts Catalogue
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b
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“ETKA” . o
c y
b
d a
s
w
l
k
e
. G
e
A
n
t
c
e
t o g
r
Capacity ⇒ page 7 .
P
♦ Loosen and tighten securing bolts and nuts for covers and
housings diagonally.
♦ Torque settings are specified for unoiled bolts and nuts.
♦ Threads of bolts secured with locking fluid must be cleaned
with a wire brush.
♦ 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.
2
Amarok 2011 ➤
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.
– Before working on electrical components, electrostatically dis‐
charge yourself (touch something that is earthed). Do not
touch connectors or »open« electronic components directly.
n AG
. Volksw age n AG
w a g e d oe

l k s s n
V o
y
o t
g u
d b
e
a r
a n
i s
r t
o e
h
t
e
u o
a r
a
s c
s c
e
l e
n p
u t
a
d n
e
t
y
t
i l
i
m
a
r b
e i
l
i
p t
t
y
o
w
n i
Contact corrosion can occur if non-approved fasteners are used
t
s
h
i
,
r
on the vehicle (bolts, nuts, washers e

etc.).
e
l s
o p
h e
w
For this reason, fastening elements with special surface coating
c
t
n
i
t
o
must be used. o
r t
h
e
t
r
c
a
Furthermore, rubber and plastic components as well as adhe‐
p
o
r
r
n e
sives are made of non-conductive
i , materials.
s
c
t
e n
s e
If there are doubts about the suitability
o
p
of fastening components, s
s
always use new parts ⇒ Electronic Parts Catalogue .
r
u
o
f
p
l n
i
a
i
f
o
r
c
r m
e
a
♦ It is recommended to use only m
genuine
m parts, since only gen‐ t
i
o
n
uine parts are approved. o
c
r
i
n
o t
h
e i
s
♦ Damage resulting from contact corrosion
t
a
v
is not covered by the o
d
warranty. i
r
p
r m
c
u
o
f e
g n
t
.
C
n
i
o
y
p
o
C y p
r
.
t
h i
g
g i
r b
h
V y
y t
p
l o
o
c
y
b k
s
w
d
e a
.
e
A
n
t
G
c
e
t o g
r
P
3
n AG
. Volksw age n AG
w a g e d o e
Amarok 2011 ➤ l k s s n
V o o t
b y g u
8-speed automatic gearbox 0CM r i s- e dEdition 04.2013 a r
a n
t
o e
h
t
e
u o
a r
a
s c
s c
e
l e
n p
u t
d
a
n
e
t
y
t
i l
i
m
a
r b
e i
l
i
p t
t
y
o
w
n i
t
s
h
i
,
r
e
e
l s
o p
h e
w
c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p r
r
n
i e
, c
s t
e n
s e
o s
p s
r o
u f
p
l n
i
a
i
f
o
r
c
r m
e
a
m t
i
m o
o n
c i
n
r
o t
h
e
t i
s
a d
v
i o
c
r
p
r
u
m
o
f e
g n
t
.
C
n
i
o
y
p
o
C y p
r
.
t
h i
g
g i
r b
h
V y
y t
p
l o
o
c y
b k
s
w
d a
e
.
e
A
n
t
G
c
e
t o g
r
P
♦ Connect and disconnect measuring and testing devices only

with the ignition switched off.
– Disconnect battery ⇒ Electrical components; Rep. gr. 27 .
4
Amarok 2011 ➤
– Disconnect battery ⇒ Electrical components; Rep. gr. 27 .
n AG
. Volksw age n AG
w a g e d o e
l k s s n
y V o o t
g u
d b
e
a r
a n
i s
r t
o e
h
t
e
u o
a r
a c
s
s c
e
l e
n p
u t
d
a
n
e
t
y
t
i l
i
m
a
r b
e i
l
i
p
t
t
y
o
w
n i
t
s
h
i
,
r
e
e
l s
o p
h e
w
c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p r
r
n
i e
, c
s t
e
n
s e
o s
p s
r o
u f
p
l n
i
a
i
f
o
r
c
r m
e
a
m t
i
m o
o n
c i
n
r
o t
h
e
t i
s
a d
v
i o
c
r
p
r
u
m
o
f e
g n
t
.
C
n i
o
y
p
o p
C
.
t r y
i
h
g i
g
b
r h
V
y t
p y
l o
o
c y
b w k
s
d a
e
. G
e
A
n
t
c
e g
t o
r
P
Amarok 2011 ➤
♦ Thoroughly clean all joints and surrounding areas before dis‐

mantling.
♦ Only use commercially available and lint-free cloths for clean‐
ing, e.g. the “WYPALL X70 / WORKHORSE” cloth from Kim‐
berly-Clark Professional.
♦ Seal open lines and connections immediately using clean
plugs or sealing caps from engine bung set - VAS 6122- .
♦ Place removed parts on a clean surface and cover them over.
Use plastic foils or lint-free cloths.
♦ If repair work cannot be performed immediately, cover new
parts which have been removed from their packing.
♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing.
♦ Protect disconnected electrical connections from dirt and wa‐ n AG
. Volksw age n AG
w a g e d o e
ter and only reconnect in dry condition. l k
V o
s s n
o t
b y g u
e d
a r
a n
i s
r t
o e
h
t
e
u o
a r
a
s c
s c
e
l e
n p
u t
d
a
n
e
t
y
t
i l
i
m
a
r b
e i
l
i
p
t
t
y
o
w
n i
t
s
h
i
,
r
e
e
l s
o p
h e
w
c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p r
r
n
i e
, c
s t
e n
s e
o s
p s
r o
u f
p
l n
i
a
i
f
o
r
c
r m
e
a
m t
i
m o
o n
c i
n
r
o t
h
e
t i
s
a d
v
i o
c
r
p
r
u
m
o
f e
g n
t
.
C
n
i
o
y
p
o
C y p
r
.
t
h i
g
g i
r b
h
V y
y t
p
l o
o
c y
b k
s
w
d
e a
.
e
A
n
t
G
c
e
t o g
r
P
6
Amarok 2011 ➤
Gearbox Identification NPZ NPY NLG NLF

code
Allocation Model Amarok 2011 ► Amarok 2011 ► Amarok 2011 ► Amarok 2011 ►
Engine 2.0 l - . V
n AG
132 kW
olksw
age n A
G
2.0 l - 132 kW 2.0 l - 132 kW 2.0 l - 132 kW
w a g e d o e
Ratio 1st gear y l k s 4.714
s n
4.714 4.714 4.714
V o o t
g u
b
e d
a r
a n
2nd gear i s
r 3.143 3.143 t 3.143 3.143
o e
h
t
e
u o
a r
3rd gear
s
s
2.106 2.106 a c
c
2.106 2.106
e
l e
n p
u
d
4th gear 1.667 1.667 t
a
n
1.667 1.667
e
t
y
t
i
m 5th gear 1.285 1.285 a 1.285
l
i 1.285
r b
e i
l
i
p
t 6th gear 1.000 1.000 1.000
t
y 1.000
o
w
n i
7th gear 0.839 0.839 0.839 0.839
t
s
h
i
,
r
e
e
l
8th gear 0.667 0.667 0.667 0.667
s
o p
h e
w
c
Reverse 3.300 3.300 3.300 3.300

t
n
i o
t
r
o
t
gear t
h
e
r
c
a o
p r
r
n
i e
, c
s t
e n
s e
o s
p s
r o
u f
p
l n
i
a
i
f
o
r
c
r m
e
a
m t
i
m o
o n
c i
n
r
o t
h
e
t i
s
a d
v
i o
c
r
p
r
u
m
o
f e
g n
t
.
C
n
i
o
y
p
o
C y p
r
.
t
h i
g
g
i
r b
h
V y
y t
p
l o
o
c
y
b k
s
w
a
Initial filling of gearbox by manufac‐ . approx. 9.0 l ATF
d
e
e
A
n
t
G
c
e
t o g
r
P
turer depending on engine
Fill of ATF cooling system approx. 0.6 l
The ATF is obtainable as a spare part.

Container size 1.0 l - Part No. ⇒ Electronic Parts Catalogue
Amarok 2011 ➤
n AG
. Volksw age n AG
w a g e d oe

l k s s n
V o
y
o t
g u
d b
e
a r
a n
i s
r t
o e
h
t
e
u o
a r
a
s c
s c
e
l e
n p
u t
d
a
n
e
t
y
t
i l
i
m
a
r b
e i
l
i
p t
t
y
o
w
n i
t
s
h
i
,
r
e
e
l s
o p
h e
w
c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p r
r
n
i e
, c
s t
e n
s e
o s
p s
r o
u f
p
l n
i
a
i
f
o
r
c
r m
e
a
m t
i
m o
o n
c
r
n
i
o t
h
e
t i
s
a d
v
i o
c
r
p
r
u
m
o
f e
g n
t
.
C
n
i
o
y
p
o
C y p
r
.
t
h i
g
g i
r b
h
V y
y t
p
l o
o
c k
s
w
y
b
d
e a
.
e
A
n
t
G
c
e
t o g
r
P
8
Amarok 2011 ➤
❑ Removing and installing

⇒ page 12 e n A
G. Volksw age n AG
a g d oe
s w

k
l s n
❑ Emptying ⇒ page b11 V
y
o o t
g u
e d
a r a
i s
r n t
o e
h
t
e
u o
a r
a
s
❑ 10 Nm +90°
e
l
s
c
c
e
n p
u t
a
d n
e
t
y
t
i l
i
m
a
❑ Removing r
e
and installing b
i
l
i
⇒ opage
p
t 25 t
y
w
n i
t
s
h
i
,
r
e
e
l s
o
h
p
e
w
n ⇒ page 10
c
t
t
i o
r
o
t
h
t
e
r
c
a o
p r
r
n
i e
, c
s t
❑ e 85 Nm
s
n
e
o s
p s
r o
u f
p
l n
i
a
i
f
o
r
c
r m
e
a
m t
i
m o
o n
c
r
n
i
o t
h
e
t i
s
a d
v
i o
c
r
p
r
u
m
o
f e
g n
t
.
C
n i
o
y
p
o p
C
.
t r y
i
h
g g
i
r b
h
V
y t
p y
l o
o
c
y
b w k
s
d
e a
. G
e
A
n
t
c
e
t o g
r
P
– Always secure converter.

An unsecured torque converter may slide out when the gearbox
is tipped.
9
Amarok 2011 ➤ n AG
. Volksw age n AG
w a g e d oe

l k
V o
s s n
o t
b y g u
e d
a r
a n
i s
r t
o e
h
t
e
u o
a r
a
s c
s c
e
l e
n p
u t
a
d n
e
t
y
t
i l
i
m
a
r b
e i
l
i
p t
t
y
o
w
n i
t
s
h
i
,
r
e
e
l s
o p
h e
w
c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p r
r
n
i e
, c
s t
e n
s e
o s
p s
r o
u f
p
l n
i
a
i
f
o
c
r m r
e
a
m t
i
m o
o n
c
r
n
i
o t
h
e
t i
s
a d
v
i o
c
r
p
r
u
m
o
f e
g n
t
.
C
n
i
o
y
p
o
C y p
r
.
t
h i
g
g i
r b
h
V y
y t
p
l o
o
c y
b k
s
w
d a
e
.
e
A
n
t
G
c
e
t o g
r
P
Therefore, always work with care.
♦ Oil seal extractor lever - VW 681-
10
Amarok 2011 ➤
– Apply oil seal extractor lever - VW 681- directly behind sealing

lip of seal to avoid damaging stop ring and lever out seal.
n AG
. Volksw age n AG
w a g e d o e
Install in reverse order of removal, observing the following: l k s s n
y V
o o t
g u
e d b a r
a n
i s
– Apply ATF to circumference and sealing lips
h
oof oil seal.
r t
e
e
t
u o
a r
a c
s
s c
e
l
Installation position:
e
n p
u t
d
a
n
e
t
y
Open side of oil seal faces gearbox. t
i l
i
m
a
r b
e i
l
i
– Using suitable thrust piece , drive t in torque converter seal to
p
o
t
y
w
stop. n
s
i
t
h
i
,
r
e
e
l s
o p
h e
w
c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p
♦ Used oil collection and extraction
i unit - V.A.G 1782-
n
r
e
r
, c
s t
e
n
s e
o s
p s
r o
u f
p
l n i
a
i
f
o
r
c
r m
e
a
m t
i
m o
o n
c i
n
r
o t
h
e
t i
s
a d
v
i o
c
r
p
r
u
m
o
f e
g n
t
.
C
n i
o
y
p
o p
C
.
t r y
i
h
g
i
g
b
r h
V
y t
p y
♦ Oil extraction unit - V.A.G 1358 A- l o
o
c k
s
w
y
b
d a
e
. G
e
A
n
t
c
e
t o g
r
P
♦ Oil extraction probe - V.A.G 1358 A/1-

If oil has become fouled by abraded material or if a major overhaul
of gearbox is being performed, drain torque converter as follows:
11
Amarok 2011 ➤
– Extract ATF from torque converter using oil extractor -

V.A.G 1358 A- and oil extraction probe - V.A.G 1358 A/1-
– Extract ATF using waste oil collection and extraction unit -

V.A.G 1782- from torque converter.
n AG
. Volksw age n AG
w a g e d oe

l k s s n
y V
o o t
g u
d b
e
a r
a n
i s
r t
o e
h
t
e
u o
a r
a
s c
s c
e
l e
n p
u t
a
d n
e
t
y
t
i l
i
m
a
r b
e i
l
i
p t
t
y
o
w
n i
t
s
h
i
,
r
e
e
l s
o p
h e
w
♦ Depth gauge c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p
– Remove
i gearbox ⇒ page 25 .
n
r
e
r
, c
s t
e n
s e
o s
p s
r o
u f
p
l n
i
a
i
f
o
r
Oil may escape
c
r
e
when the torque converter is pulled out of the m
a
gearbox. m t
i
o
m n
o
c i
n
r
t
h
– Remove torque
t converter from gearbox.
e
o
i
s
a d
v
i o
c
r
p
r
u
m
o
f e
g n
t
.
C
n i
o
y
p
o p
C
.
t r y
i
h
g i
g
b
r h
V
y t
p y
l o
o
c
y
b w k
s
d a
e
. G
e
A
n
t
c
e
t o g
r
P
12
Amarok 2011 ➤
– Push torque converter into gearbox to stop.

The torque converter is properly installed when the gearbox can
be pushed against the engine flange »without force«.
– If this is not the case, fit the torque converter again. Then check
the installation dimension ⇒ page 13 .
• 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
26.25 mm.
– Ensure that the torque converter does not slide »forwards«
during the installation of the gearbox.
The torque converter is properly installed when the gearbox can

be pushed against the engine flange »without force«.
Secure drive plate on torque converter.
– After installing gearbox, check ATF level and top up
⇒ page 51 . g e n A
G. Volksw age n AG
w a d oe

l k s s n
y V
o o t
g u
d b
e
a r
a n
i s
r t
♦ ⇒ “1.1 Assembly overview u t h- otorque converter”, page 9
e
e
o
a r
a
s c
s c
e
l e
n p
u t
a
d n
e
t
y
t
i l
i
m
a
r b
e i
l
i
p t
t
y
o
w
n i
t
s
h
i
,
r
e
e
l s
o p
h e
w
c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p r
r
n
i e
, c
s t
e n
s e
o s
p s
r o
u f
p
l n
i
a
i
f
o
r
c
r m
e
a
m t
i
m o
o n
c i
n
r
o t
h
e
t i
s
a d
v
i o
c
r
p
r
u
m
o
f e
g n
t
.
C
n
i
o
y
p
o p
C
.
t r y
i
h
g
i
g
b
r h
V y
y t
p
l o
o
c k
s
w
y
b
d a
e
. G
e
A
n
t
c
e g
t o
r
P
13
Amarok 2011 ➤
e n A
G . Volksw age n AG
w a g d o e
l k s s n
V o
y
o t
g u
d b
e
a r
a n
i s
r t
o e
h
t
e
u o
a r
a
s c
s c
e
l e
n p
u t
d
a
n
e
t
y
t
i l
i
m
a
r b
e i
l
i
p t
t
y
o
w
n i
t
s
h
i
,
r
e
e
l s
o p
h e
w
c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p r
r
n
i e
, c
s t
e n
s e
o s
p s
r o
u f
p
l n
i
a
i
f
o
r
c
r m
e
a
m t
i
m o
o n
c
r
n
i
o t
h
e
t i
s
a d
v
i o
c
r
p
r
u
m
o
f e
g n
t
.
C
n i
o
y
p
o p
C
.
t r y
i
h
g i
g
b
r h
V y
y t
p
l o
o
c k
s
w
y
b
d a
e
. G
e
A
n
t
c
e
t o g
r
P
14
Amarok 2011 ➤
❑ Renew after each re‐

moval.
❑ For attaching handle to
selector lever
❑ Removing ⇒ page 17
❑ Is removed together
with handle.
e n A
G . Volksw age n AG
w a g d oe

l k s s n
y V
o o t
g u
d b
e
a r
a n
i s
r t
o e
h
t
e
u o
a r
a
s c
s c
e
l e
n p
u t
d
a
n
e
t
y
t
i l
i
m
a
r b
e i
l
i
p t
t
y
o
w
n i
t
s
h
i
,
r
e
e
l s
o p
h e
w
c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p r
• The starter must not operate in

i ,the selector lever positions “S”, r
n e
c
s
“D”, “R” and “Tiptronic gate”. e s
t
n
e
o s
s
• When the vehicle is moving at p speeds above 5 km/h and the
u
r o
f
selector lever is shifted to position

p
a
“N”, the solenoid for selector
l n
i
f
o
lever lock must not engage and c rblock selector lever. Selector
i
m r
lever can be shifted into a driving e

m range. a
t
i
m o
o n
• When the vehicle is moving at speeds
c
r below 2 km/h (almost n
i
t
h
stationary) and the selector lever is e
tshifted to position “N”, the
o
i
s
d
solenoid for selector lever lock should a
v
i only engage after about o
c
r
u
1 second. Selector lever cannot be shifted p
r
o
f
out of “N” position m
e
until brake pedal is depressed. g n
t
.
C
n
i
o
y
p
o p
C
.
t r y
i
h
g g
i
r b
h
V
y t
– Do not operate brake pedal.
p y
l o
o
c k
s
w
y
b
d a
e
. G
e
A
n
t
c
e
t o g
r
P
15
Amarok 2011 ➤
• Selector lever is locked and cannot be shifted out of “P” posi‐

tion with the lock button pressed on selector lever handle.
Solenoid for selector lever lock - N110- blocks selector lever.
– Press brake pedal and keep it pressed down.
• Solenoid for selector lever lock - N110- releases selector lever.
It is possible to shift into a driving gear. With lock button press‐
ed on selector lever handle slowly shift selector lever through
positions “R, N, D, S” starting at position “P”. Check whether
selector lever position display - Y6- in dash panel insert cor‐
responds to selector lever position.
– Do not operate brake pedal.

• After a short waiting time: Selector lever is locked and cannot
be shifted out of “N” position despite lock button being pressed
on selector lever handle. Solenoid for selector lever lock -
N110- blocks selector lever.
– Operate brake pedal.
• Solenoid for selector lever lock - N110- releases selector lever.
“D” position can be engaged.
– Shift selector lever into “Tiptronic gate”.

• Illuminated “D” symbol in selector lever position display - Y26-
must go out and “+” and “–” symbols must light up.
Simultaneous illumination of all selector lever position display

segments indicates gearbox emergency g e n A
Grunning
. Volksw agmode.
e n A
G d
w a oe

l k s s n
y V lever
o o t
– Check and adjust selector
d b
cable. g u
a r
e a n
i s
r t
o e
h
t
e
u o
a r
a
s c
s c
e
l e
n p
u t
a
d n
e
t
y
t
i l
i
m
a
r b
e i
l
i
p t
t
y
♦ Selector o lever cannot be moved out of “P” position when bat‐
n
w
i
t
tery is disconnected or flat.
s
h
i
,
r
e
e
l s
o p
♦ Operating
w
emergency release causes selector lever lock sol‐
h e
c
enoid
n - N110- to release lock when it is de-energised.
i
t
t
o
r
o
t
h
t
e
r
c
– Unclip selector cover -1- from trim -arrows-.
a
p
o
r
r
n
i e
c
– Only raise trim far enough until emergency release is acces‐
,
s t
e n
e
sible.
s
o s
s
p
r o
u f
p
l n
i
a
i
f
o
r
c
r m
e
a
m t
i
m o
o n
c
r
n
i
o t
h
e
t i
s
a d
v
i o
c
r
p
r
u
m
o
f e
g n
t
.
C
n i
o
y
p
o p
C
.
t r y
i
h
g g
i
r b
h
V
y t
p y
l o
o
c
y
b w k
s
d
e a
. G
e
A
n
t
c
e
t o g
r
P
16
Amarok 2011 ➤
– Press emergency release lever downwards in

-direction of arrow- using your finger or a screwdriver and, at
the same time, push button of handle and shift selector lever
out of position “P”.
– Install selector cover.
♦ Hose clip pliers - V.A.G 1275- n AG

. Volksw age n AG
w a g e d oe

l k s s n
V o
y
o t
g u
d b
e
a r
a n
i s
r t
o e
h
t
e
u o
a r
a
s c
s c
e
l e
n p
u t
d
a
n
e
t
y
t
i l
i
m
a
r b
e i
l
i
p t
t
y
o
w
n i
t
s
h
i
,
r
e
e
l s
o p
h e
w
c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p r
r
n
i e
, c
– Shift selector lever to position
e“D”.
s t
n
e
s
o s
s
– Unclip selector cover -1- from
p
trim -arrows-.
u
r o
f
p
n
i
– Pull connector off selector cover and pull gaiter over handle.
l
a
i
f
o
r
c
r m
e
a
m t
i
m o
o n
c
r
n
i
o t
h
e
t i
s
a d
v
i o
c
r
p
r
u
m
o
f e
g n
t
.
C
n
i
o
y
p
o p
C
.
t r y
i
h
g i
g
b
r h
V y
y t
p
l o
o
c
y
b w k
s
d a
e
. G
e
A
n
t
c
e
t o g
r
P
17
Amarok 2011 ➤
– Remove clamp -arrow-.

– Pull handle off selector lever, without pressing button.
Handle is removed together with selector cover.

e n A
G . Volksw age n AG
w a g d oe

l k s s n
y V
o o t
g u
d b
e
a r
a n
i s
r t
o e
h
t
e
u o
a r
a
s c
s c
e
l e
n p
u t
a
d n
e
t
y
t
i l
i
m
a
r b
e i
l
i
p t
t
y
o
w
n i
t
s
h
i
,
r
e
e
l
Install in reverse order of removal, observing the ofollowing:
s
p
h e
w
c
t
• Selector lever is in position “D”. n

i
r
t
o
o
t
h
t
e
r
c
a o
p r
r
n
i , e
c
s t
e n
s e
o s
p s
o
♦ The button might be pressed into the handle. u
p
Do not install a
r
f
n
i
handle with the button pressed in. a

l
i
f
o
c
r
r
m
♦ New handle is supplied with installation guard. e
Do not remove
m
a
t
i
o
guard until just before installing. To remove, pull
mit out.
o n
c i
n
r
o t
h
e
t i
s
If the button was pressed in by mistake, the installation position a
v
i o
d
c
can be restored. To do this, push installation guard fully in whilst r
p
r
u
m
button is pressed, release button and pull installation guard
f out
o
g
e
n
t
.
C
n
again. Button engages in installation position. i
y
p
o o
p
C
.
t r y
i
– Push handle with new clamp fully onto selector lever until it i r h
g b
g
h
V
y t
can be felt to engage. p y
l o
o
c k
s
w
y
b d a
e
. G
e
A
n
t
c
e
t o g
– Press button in selector lever handle.
r
P
If not installed correctly, button remains inserted in handle after

being pressed. Handle must be re-installed.
– Secure clamp -arrow- with hose clip pliers - V.A.G 1275- .
18
Amarok 2011 ➤
♦ Removal lever - 80 - 200-
– Remove transfer box ⇒ Power transmission; Rep. gr. 39 ;

Transfer box; Removing and installing transfer box .
– Remove selector lever handle ⇒ page 17 .
– Pull securing clip -arrow- in -direction of arrow- off selector
lever cable -1- and out of guide.
n AG
. Volksw age n AG
w a g e d oe

l k s s n
y V
o o t
b g u
e d
a r
a n
i s
r t
o e
h
t
e
u o
a r
a
s c
s c
e
l e
n p
u t
a
d n
e
t
y
t
i l
i
– m Press selector lever cable on ball head -arrow- off gearbox
a
r b
e i
l
p
t
using removal lever - 80-200- . Then pull cable -1- in i
t
y
o
w
n -direction of arrow- out of guide and lay to side. i
t
s
h
i
,
r
e
e
l s
o p
h e
w
c
t
n
i
t
o
r
o
t
h
t
e
r
a The number of connectors depends on the vehicle's equipment. c
o
p r
r
n
i e
, c
s t
e n
s e
o s
p s
r o
u f
p
l n
i
a
i
f
o
c
r m r
e
a
m t
i
m o
o n
c i
n
r
t
o h
e
t i
s
a d
v
i o
c
r
p
r
u
m
o
f e
g n
t
.
C
n
i
o
y
p
o p
C
.
t r y
i
h
g i
g
b
r h
V y
y t
p
l o
o
c k
s
w
y
b
d
e a
.
e
A
n
t
G
c
e
t o g
r
P
19
Amarok 2011 ➤
– Unclip selector lever frame -1- -arrows- and disconnect all

connectors.
– Unscrew nuts -arrows- and remove selector mechanism

downwards.
Install in reverse order of removal, observing the following:

– Tighten nuts of selector unit.
– Install transfer box ⇒ Power transmission; Rep. gr. 39 ;
Transfer box; Removing and installing transfer box .
– Install selector lever handle ⇒ page 17 .
Nuts of selector unit 8 Nm
e n A
G . Volksw age n AG
w a g d oe

l k s s n
y V
o o t
g u
d b
e
a r
a n
i s
♦ Removal lever - 80-200- h
o
r t
e
e
t
u o
a r
a
s c
s c
e
l e
n p
u t
a
d n
e
t
y
t
i l
i
m
a
r b
e i
l
i
p t
t
y
o
w
n i
t
s
h
i
,
r
e
e
l s
o p
h e
w
c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p r
r
n
i e
, c
s t
e n
s e
o s
p s
r o
u f
– Move selector lever to “P” position. p
l n
i
a
i
f
o
r
c
r m
e
a
m t
i
m o
o n
c i
n
r
o t
h
e
t i
s
a d
v
i o
c
r
p
r
u
m
o
f e
g n
t
.
C
n
i
o
y
p
o p
C
.
t r y
i
h
g i
g
b
r h
V
y t
p y
l o
o
c k
s
w
y
b
d
e a
. G
e
A
n
t
c
e
t o g
r
P
20
. Volksw age n AG
n AG
a g e
w
d o e
l k s s n
V o
y
o t
g u
d b
e Amarok 2011 ➤ a r
a n
i s
r t
o
u
h
t 8-speed automatic gearbox 0CM - Editione 04.2013
e
o
a r a
s c
s c
e
l e
– Press selector lever cable on ball head n -arrow- off gearbox
u
p
t
d
a
using removal lever - 80-200- . i e
t
t
n
y
l
i
m
a
r b
– Move selector lever from “P” to p e
“D”. i
l
i
t
t
y
o
w
n
• Selector lever cable must move
s easily and smoothly. i
i
t
h
,
r
e
e
l
– Move selector lever to “P” position.
s
o p
h e
w
c
t
n
– Move selector shaft lever on gearbox to position “P”. Locking
i
r
t
o
o
lever must engage in parking lock wheel so that both front
t
h
t
e
r
c
wheels are blocked (cannot pbe
a

turned together in same direc‐ o
r
tion). i , n e

r
c
s t
e n
• It must be possible to push o
selector lever cable onto selector
s e
s
s
shaft lever. Adjust selector lever
p
u
cable if necessary.
r o
f
p
n
i
– Carefully press selector lever ccable onto selector shaft lever.

l
a
i
f
o
r
m
Do not bend selector shaft lever e or selector can no longer be
r
a
precisely adjusted. m t
i
m o
o n
c i
n
r
o t
h
e
t i
s
a d
o
– Move selector lever to “P” position. v
i
r c
u
p
r m
o
f e
– Remove selector lever cable from selector
g shaft lever. n
t
.
C
n
i
o
y
p
o p
C
.
t r y
i
– Move selector shaft lever on gearbox to position
i
r “P”. Locking h
g b
g
h
V y
y t
lever must engage in parking lock wheel so that p
both
o
c y
b front w
l o
k
s
a
wheels are blocked (cannot be turned together in same direc‐
d
e
. G
e
A
n
t
c
e
t o g
r
P
tion).
– Loosen bolt -2- and press selector lever cable -1- onto selector
shaft lever.
Do not pull selector lever backwards or forwards when tightening

the bolt, otherwise setting could be falsified.
– Tighten bolt for selector lever cable.
Bolt for selector lever cable 12 Nm
21
Amarok 2011 ➤
♦ Torque wrench - V.A.G 1331-

e n A
G . Volksw age n AG
w a g d oe

l k s s n
y V
o o t
g u
d b
e
a r
a n
– Press selector lever cable on ball head -arrow- off gearbox i s
r t
o e
h
t
e
using removal lever - 80-200- . Then pull u cable -1- in
a
o
r
a
s
-direction of arrow- out of guide and l elay to side.
c
s c
e
n p
u t
a
d n
e
t
y
t
i l
i
m
a
r b
e i
l
i
p t
t
y
o
w
n i
t
s
h
i
,
r
e
e
l s
o p
h e
w
c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p r
r
n
i e
, c
s t
n
– Unscrew bolts -arrows- for e
rear propshaft -1- and remove
s e
s
propshaft from flange -2-. o
p
r o
s
u f
p
l n
i
a
i
f
o
r
c
r m
e
a
m t
i
m o
o n
c i
n
r
o t
h
e
t i
s
a d
v
i o
c
r
p
r
u
m
o
f e
g n
t
.
C
n i
o
y
p
o p
C
.
t r y
i
h
g i
g
b
r h
V
y t
p y
l o
o
c k
s
w
y
b
d a
e
. G
e
A
n
t
c
e
t o g
r
P
22
Amarok 2011 ➤
– Tie up propshaft -1- at a suitable location using wire -arrow-.
– Position engine and gearbox jack - V.A.G 1383 A- under trans‐

fer box.
– Remove securing bolts for gearbox cross member -1- and
gearbox mounting -arrows-.
– Remove gearbox crossmember with gearbox mounting.
Lower gearbox carefully with engine and gearbox jack - V.A.G

1383 A- until cable support bracket bolts can be accessed more
easily.
– Lower gearbox.
– Unscrew bolts -arrows- from cable support bracket -1- and re‐
move cable support bracket.
e n A
G . Volksw age n AG
w e s a g d o
l k s
Install in reverse Vorder
o of removal, observing the
n o following:
t g
b y u a
e d r a
i s
r
n t
o e
h
t
e
u o
a r
a
s c
s c
e
l e
n p
u t
a
d
Bolt for selector lever cable 12 Nm n
e
t
y
t
i l
i
m
a
r
e Bolts for cable support bracket 10 Nm b
i
l
i
p t
t
y
o
n
Bolts for gearbox carrier on lad‐ 50 Nm +90° w
i
t
s
der frame1)
h
i
,
r
e
e
l s
o
Bolts for gearbox carrier on 20 Nm +90°
p
h e
w
c
gearbox mounting 1)
t
n
i
t
o
r
o
t
Bolts for gearbox mounting on 50 Nm +90°

h
t
e
r
c
a
p
n
gearbox 1) o
r
r
i e
c
Bolts for propshaft1) 50 Nm +90°
,
s t
e n
s e
o s
p s
r
u
1) Renew. o
f
p
l n
i
a
i
f
o
r
c
r m
e
a
m t
i
m o
o n
c i
n
r
o t
h
e
t i
s
a d
v
i o
c
r
p u
m
– o
Remove sump ⇒ page 58 .
r
f e
g n
t
.
C
n
i
o
y
– Remove
p
o mechatronic unit ⇒ page 62 . p
C .
t r y
i
i h
g g
– Detach selector mechanism from gearbox ⇒ V
page b 19 .
r h
t
y
p y
l o
o c k
s
w
y
b
d
e a
.
e
A
n
t
G
c
e
t
o
g
r
P
23
Amarok 2011 ➤
Remove any residues of old locking pin from gearbox.
– Drive out locking pin with a drift.
– Pull gearbox selector lever and seal out of gearbox.
♦ Remove any residues of old locking pin from gearbox.

♦ Renew seal and drive it in as far as stop using a suitable thrust G. Volksw age n AG
w a
g e n A d o e
s
piece.
l
V o
k s n
o t
g b y u a
e d r a
♦ Drive in new locking pin so that it is flush. i s
r
n t
o e
h
t
e
u o
a r
a c
s
s c
e
l e
n p
u t
d
a
n
e
t
y
t
i l
i
m
a
r b
e i
l
i
p t
t
y
o
w
n i
t
s
h
i
,
r
e
e
l s
o p
h e
w
c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p r
r
n
i , e
c
s t
e n
s e
o s
p s
r o
u f
p
l n
i
a
i
f
o
r
c
r m
e
a
m t
i
m o
o n
c i
n
r
o t
h
e
t i
s
a d
v
i o
c
r
p
r
u
m
o
f e
g n
t
.
C
n
i
o
y
p
o p
C
.
t r y
i
h
g i
g
b
r h
V
y t
p y
l o
o
c k
s
w
y
b
d a
e
. G
e
A
n
t
c
e
t o g
r
P
24
Amarok 2011 ➤
♦ Fitting tool - 3046-

♦ Engine support - T50015-
♦ Lifting tackle - 2024 A-
♦ Support bridge - 30 - 211 A-
♦ Engine bung set - VAS
6122-
n AG
. Volksw age n AG
w a g e d o e
l k s s n
V o
y
o t
g u
d b
e
a r
a n
i s
r t
o e
h
t
e
u o
a r
a c
s
s c
e
l e
n p
u t
d
a
n
e
t
y
t
i l
i
m
a
r b
e i
l
i
p
t
t
y
o
w
n i
t
s
h
i
,
r
e
e
l s
o p
h e
w
c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p r
r
n
i e
, c
s t
e n
s e
o s
p s
r o
u f
p
l n
i
a
i
f
o
r
c
r m
e
a
m t
i
m o
o n
c i
n
r
o t
h
e
t i
s
a d
v
i o
c
r
p
r
u
m
o
f e
g n
t
.
C
n
i
o
y
p
o
C y p
r
.
t
h i
g
g i
r b
h
V y
y t
p
l o
o
c
y
b k
s
w
d a
e
.
e
A
n
t
G
c
e
t o g
r
P
25
Amarok 2011 ➤
♦ Torque wrench - V.A.G

1331-
♦ Torque wrench - V.A.G
1332-
♦ Engine and gearbox jack -
V.A.G 1383 A-
n AG
. Volksw age n AG
a g e
w d o e
l k s s n
y V
o o t
g u
d b
e
a r
a n
i s
r t
o e
h
t
e
u o
a r
a c
s
s c
e
l e
n p
u t
d
a
n
e
t
y
t
i l
i
m
a
r b
e i
l
i
p
t
t
y
o
w
n i
t
s
h
i
,
r
e
e
l s
o p
h e
w
c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p r
r
n
i e
, c
s t
e
n
s e
o s
p s
r o
u f
♦ p
l
a
Comply with rules for cleanliness when working on gearbox n
i
f
o
⇒ page 6 .
c
r
i
m r
e
a
♦ m
Observe
m repair instructions ⇒ page 1 . n
t
i
o
o
c i
n
♦ Observe safety precautions ⇒ page 4 .
r
o t
h
i
e t s
a d
o
♦ Seal open lines and connections using clean plugs from en‐
v
i
r
u c
p
m
gine bung f set - VAS 6122- .
r
o e
n
g t
.
C
n i
o
y
p
o
– Raise vehicle .⇒ Maintenance ; Booklet 11 .
p
C
t r y
i
h
g i
g
b
r h
V
y t
– If fitted, remove engine/gearbox guard ⇒ General lbody re‐
p y
o
c k o
y
b s
w
a
pairs, exterior; Rep. gr. 66 ; o
Engine/gearbox guard; Removing
d
e
. G
e
A
n
t
c
e
t g
r
P
and installing engine/gearbox guard .
– Remove starter ⇒ Vehicle electrics; Rep. gr. 27 ; Starter; Re‐
moving and installing starter .
– Remove front silencer ⇒ Power unit; Rep. gr. 26 ; Exhaust
system; Exhaust pipes/silencers .
– Remove front propshaft ⇒ Transfer box and final drives; Rep.
gr. 39 ; Propshaft; Removing and installing front propshaft .
26
n AG
. Volksw age n AG
w a g e d o e
l k s s n
y V
o o t
g u
d b
e Amarok 2011 ➤
a r
a n
i s
r t
o e
h
t
u 8-speed automatic
o gearbox 0CM - Edition 04.2013
e
a r
a c
s
s c
e
l e
n p
u t
d
a
n
e
t
y
t
i l
i
m
a
r b
e i
l
i
p
t
t
y
It is not nnecessary to remove rear propshaft.

o
w
i
t
s
h
i
,
r
e
e
l s
o
– Unscrew bolts -arrows- for rear propshaft -1- and remove
h
p
e
w
propshaft from flange -2-.
c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p r
r
n
i e
, c
s t
e
n
s e
o s
p s
r o
u f
p
l n
i
a
i
f
o
r
c
r m
e
a
m t
i
m o
o n
c i
n
r
o t
h
e
t i
s
a d
v
i o
c
– Tie up propshaft
r
r
-1- at a suitable location using wire -arrow-.
p u
m
o
f e
g n
t
.
C
n
i
o
y
p
o p
C
.
t r y
i
h
g i
g
b
r h
V
y t
p y
l o
o
c
y
b w k
s
d a
e
. G
e
A
n
t
c
e g
t o
r
P
– Unlock connector -arrow- by turning it anti-clockwise in

-direction of arrow-.
– Unclip wiring harness from gearbox -1- -arrows- and lay to

side.
27
Amarok 2011 ➤

– Press selector lever cable on ball head -arrow- off gearbox

using removal lever - 80-200- . Then pull cable -1- in
-direction of arrow- out of guide and lay to side.
n AG
. Volksw age n AG
w a g e d oe

l k s s n
V o
y
o t
g u
d b
e
a r
a n
i s
r t
o e
h
t
e
u o
a r
– Remove particulate s
s filter bracket -1- from gearbox. To do this, a
c
c
e
l e
unscrew u n
bolts -arrows-. p
t
a
d n
e
t
y
t
i l
i
m
a
r b
e i
l
i
p t
t
y
o
w
n i
t
s
h
i
Only l eturn crankshaft in direction of engine rotation -arrow-.
,
r
e
s
o p
h e
w
c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p r
r
n
i e
, c
s t
e n
s e
o s
p s
o
– u
Turn crankshaft -1- using an offset ring spanner -arrow- until
r
f
p
the
a torque converter bolts are accessible.
l
i
n
i
f
o
c
r
r
m
e
a
m t
i
m o
o n
c
r
n
i
o t
h
e
t i
s
♦ Counterhold crankshaft with ring spanner when loosening tor‐
a d
v
i o
c
que converter.
r
p
r
u
m
o f e
g n
t
.
♦ The torque i
converter
y
p is secured with three bolts. Therefore o C
n
turn crankshaft by 120° to access the bolts one after another.

o p
C .
t r y
i
h g g
i
r b
h
V y
y t
p
o
c o
l
k
y
b s
w
d
e a
. G
e
A
n
t
c
e
t o g
r
P
28
Amarok 2011 ➤
– Unscrew bolts -arrow- from torque converter -1-.
Catch oil which runs out. Seal ATF lines and gearbox using clean
plugs from engine bung set - VAS 6122- .
. Volksw age n AG
n AG
a g e
w d oe

l k s s n
y V
o o t
– Unscrew bolt -1- for ATF lines -arrows- e from
d bgearbox and dis‐ g u
a r
a n
i s
connect ATF lines. r
o
h
t
e
e
t
u o
a r
a
s c
s c
e
l e
n p
u t
a
d n
e
t
y
t
i l
i
m
a
r b
e i
l
i
p t
t
y
o
w
n i
t
s
h
i
,
r
e
e
l s
o p
h e
w
c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p r
r
n e
– Unscrew securing bolt s
-arrow- for ATF lines -1-.
i , c
t
e n
s e
o s
p s
r o
u f
p
l n
i
a
i
f
o
r
c
r m
e
a
m t
i
m o
o n
c
r
n
i
o t
h
e
t i
s
a d
v
i o
c
r
p
r
u
m
o
f e
g n
t
.
C
n i
o
y
p
o p
C
.
t r y
i
h
g g
i
r b
h
V
y t
p y
l o
o
c k
s
– Unscrew bolt securing ATF double line -1- from bracket -2- and w
b y
d a
e
. G
e
A
n
t
c
e g
lay line together with clamp -arrow- to side.
t o
r
P
29
Amarok 2011 ➤
– Secure adapter - 2024 A/1- on subframe with fitting tool -

3046- .
– Secure engine support - T50015- and preload it slightly.
– Remove securing bolts for gearbox mounting -arrows-.

– Place engine and gearbox jack - V.A.G 1383 A- under gearbox
crossmember.
– Remove securing bolts for gearbox cross member -1-.
– Lower gearbox crossmember with engine and gearbox jack -
V.A.G 1383 A- and remove.
Bolts 4 and 5 have already been removed during removal of s tart‐

er.
n AG
. Volksw age n AG
w a g e d oe

– Unscrew engine/gearbox l k s s
y Vsecuring bolts -1 through 10- except
n o o
t g
b u a
for one securing bolt. s e d r a
i
r n t
o e
h
t
e
u o
a r
a
s c
s c
e
l e
n p
u t
a
d n
e
t
y
t
i l
i
m
a
r b
e i
l
i
p t
t
y
o
w
n i
t
s
h
i
,
r
e
e
l s
o p
h e
w
c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p r
– Position
n
i , engine and gearbox jack - V.A.G 1383 A- with a soft r
e
c
foam
e surface -arrow- under gearbox -1- and also secure gear‐
s t
n
e
s
box o using a tensioning belt.
p
s
s
r o
u f
– Remove
p last engine/gearbox connecting bolt.
l n i
a
i
f
o
c
r
r
m
e
a
m t
i
m o
o n
c i
n
r
o t
h
e i
s
Only remove
t the gearbox with the help of a second mechanic.
a
v
d
o
i c
r
p
r
u
m
o
f e
– Press gearbox
noff
g engine (dowel sleeves) and pull out to rear. n
t
.
i C
o
y
p
o p
C
.
t r y
i
h
g i
g
b
r h
V
y t
p y
l o
o
c y
b w k
s
d a
e
. G
e
A
n
t
c
e
t o g
r
P
30
Amarok 2011 ➤
– Lower gearbox -1- carefully with engine and gearbox jack -

V.A.G 1383 A- .
– Use support bridge - 30 - 211 A- to secure torque converter in

gearbox and prevent it falling out.
♦ Always renew bolts that are tightened with specified tightening

angle.
♦ Renew self-locking nuts and bolts.
♦ All cable ties which were opened or cut during removal must
be renewed at the same locations.
♦ Check whether dowel sleeves for aligning engine and gearbox
are fitted in cylinder block and install if necessary.
♦ If dowel sleeves are not fitted, difficulties shifting gears, clutch G. Volksw age n AG
w a
g e n A d o e
k
l s s n
problems and possible noises from the gearbox (rattling V o of
y
o t
g u
b
d
gears which are not engaged) could occur. s
i
e
a r
a n
r t
o e
h
t
e
u o
a r
a
s c
s c
e
l e
n p
u t
d
a
n
e
t
y
t
i l
i
m
a
r b
e i
l
i
p
t
t
y
o
w
n i
t
s
h
i
,
r
e
e
l s
o p
h e
w
c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p r
r
n
i , e
c
s t
e n
s e
– If ATF is dirty or if an exchange gearbox
o
p
is to be installed, clean s
s
o
ATF cooler and ATF lines ⇒ page 49 .
r
u f
p
l n
i
a f
o
– Reassemble all electrical connections, lines, hoses and con‐
i
r
c
r m
e
nectors that were disconnected during
m removal. a
t
i
m o
o n
c i
n
r
o t
h
e
t i
s
a d
v
i o
c
r
p
r
u
m
o
f e
g n
t
.
C
n i
o
y
p
o p
C
.
t r y
i
h
g i
g
b
r h
V
y t
p y
l o
o
c k
s
w
y
b
d a
– Before installing gearbox, ensure that torque converter is t c e . G e
e
A
n
t o g
r
P
properly seated in gearbox ⇒ page 12 .
31
Amarok 2011 ➤
– Check installation dimension -a- ⇒ page 13

– Therefore, when securing gearbox to engine, check frequently
that the torque converter »moves freely« and is not being
pinched.
– Install starter ⇒ Vehicle electrics; Rep. gr. 27 ; Starter; Re‐
moving and installing starter .
– Install front silencer ⇒ Power unit; Rep. gr. 26 ; Exhaust sys‐ n AG
. Volksw age n AG
w a g e d oe

l k s s n
tem; Exhaust pipes/silencers . y V
o o t
g u
d b a r
i
r s e a n
– Install front propshaft ⇒ Transfer box and final drives; Rep. h
t
o
t
e
e
u o
gr. 39 ; Propshaft; Removing and installing front propshaft
s
a . r
a
c
s c
e
l e
n p
u t
a
d n
e
t
y
– If fitted, install engine/gearbox guard ⇒ General body i
m
repairs, t l
i
a
r b
exterior; Rep. gr. 66 ; Engine/gearbox guard; Removing e
p
and i
l
i
t
t
y
installing engine/gearbox guard . o
n
w
i
t
s
h
i
After installing, check ATF level and top up if necessary ,
r
e
e
l s
o
⇒ page 51 . h
p
e
w
c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p r
r
n
i e
, c
s t
e n
s e
o s
p s
r o
u f
p
l n
i
a
i
f
o
r
c
r m
e
a
m t
i
m o
o n
c i
n
r
o t
h
e
t i
s
Item 2, 3, 6: M12×70 80 Nm a
v
i
d
o
c
r
p u
m
Item 1, 10: M12×180×49 80 Nm r
o
f e
g n
t
.
C
n
Item 7, 8: M10×50 45 Nm i
y
p
o o
p
C r y
i
Item 9: M10×115×90 45 Nm
.
t
h
g
i
g
b
r h
V y
y t
p
Item 4: M12×70 80 Nm l o
o
c k
s
w
y
b
d a
e
. G
e
A
n
t
c
e g
t o
Item 5: M12×60 80 Nm
r
P
Drive plate to torque converter 85 Nm

Bolt for selector lever cable 12 Nm
Bolts for gearbox carrier on lad‐ 50 Nm +90°
der frame1)
gearbox mounting 1)
Bolts for gearbox mounting on 50 Nm +90°
gearbox1)
Bolts for propshaft1) 50 Nm +90°
32
Amarok 2011 ➤
♦ Puller - T10055-
♦ Adapter - T10055/2-
♦ Sleeve - T10180-
♦ Thrust piece - T10186-
e n A
G . Volksw age n AG
w a g d o e
l k s s n
V o
y
o t
g u
d b
e
a r
a n
i s
r t
o e
h
t
e
u o
a r
a
s c
s c
e
l e
n p
u t
d
a
n
e
t
y
t
i l
i
m
a
r b
e i
l
i
p
t
t
y
o
w
n i
t
s
h
i
,
r
e
e
l s
o p
h e
w
c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p r
r
n
i e
, c
s t
e n
s e
o s
p s
r o
u f
p
n
i
– Remove l
a transfer box ⇒ Power transmission; Rep. gr. 39 ;

i
f
o
r
Transfer
c
r box; Removing and installing transfer box . m
e
a
m t
i
o
– To pull m
o out seal, screw sheet metal screw of about 4 mm di‐ n
c n
i
ameter r
into
o
seal -arrow-. t
h
e
t i
s
d
♦ Screw in a
self-tapping
v
i screw so its is clamped between seal o
c
r
u
m
and metal cover. p
r
o
f e
g n
t
.
C
n
i
♦ Do not screw in y
sheet
p
o
metal screw too far to avoid damaging o
bearing behind it. t
p
C . r
i
y
h g g
i b
h r
V y
y t
– Pull out seal using puller - y
T10055- .
p
l o
o
c
b k
s
w
d a
e
. G
e
A
n
t
c
e
t o g
r
P
33
n AG
. Volksw age n AG
w a g e d oe

l k s s n
V o
y
o t
g u
d b
e
a r
a n
i s
r t
Amarok 2011 ➤ u t h o
e
e
o
a r
a
s
8-speed automatic
e
l
s gearbox 0CM - Edition 04.2013 c
c
e
n p
u t
a
d n
e
– Especially coat isealing lips of new seal with ATF.
t
t
y
l
i
m
a
r b
e i
l
i
p t
t
y
o
w
n i
t
s
h
i
,
r
e
e
l s
o p
h e
w
c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p r
r
n
i e
, c
s t
e n
s e
o s
p s
r o
u f
p
l n
i
a
i
f
o
r
– First put sleeve
r
c
- T10180- on output shaft to prevent damage m
e
a
to seal. m t
i
m o
o n
c i
n
– Drive in new oil seal to stop using thrust piece - T10180- . Do
r
o t
h
i
e s
not cant oil seal
t
a in the process.
v
d
o
i c
r
p u
m
– Install transfer box o
f ⇒ Power transmission; Rep. gr. 39 ;
r
e
g n
Transfer box; Removing y and installing transfer box .
n
i C
t
.
p
o o
p
– Finally, check ATF level t
and
C
. top up ⇒ page 51 . r y
i
h
g i
g
b
r h
V y
y t
p
l o
o
c
y
b w k
s
d
e a
. G
e
A
n
t
c
e
t o g
r
P
34
Amarok 2011 ➤
♦ Engine and gearbox jack - V.A.G 1383 A-
G. Volksw age n AG
w a
g e n A d oe

l k s s n
y V
o o t
g u
d b
e
a r
a n
i s
r t
o e
h
t
e
u o
a r
a
s c
s c
e
l e
n p
u t
a
d n
e
t
y
t
i l
i
m
a
r b
e i
l
i
p t
t
y
o
w
n i
t
– Raise vehicle ⇒ Maintenance ; Booklet e s11 .
h
i
,
r
e
l s
o p
– Mark installation position of gearbox crossmember.
w
h e
c
t
n
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t
o
– Unscrew securing bolts for gearbox mountings
o -arrows-.
r t
h
e
t
r
c
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a
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p
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C
.
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g i
g
b
r h
V
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o
c
y
b w k
s
d a
e
. G
e
A
n
t
c
e
t o g
r
P
35
Amarok 2011 ➤
– Position engine and gearbox jack - V.A.G 1383 A- under gear‐

box.

– Insert gearbox crossmember back into previously marked po‐
sition.
♦ Arrow on gearbox crossmember points in direction of travel.

♦ Carefully clean and degrease gearbox crossmember before
installation. Then carry out the following anti-corrosion meas‐
ures: G. Volksw age n
w a
g e n A AG d
o e
l k s s
♦ Apply new primer and new paint on all “bare metal” and
y V t g “dam‐
n o o
b
d of gearbox crossmember (with a spray
u a
aged” paint surfaces r s
i
e r a
n t
o
can or brush). u t
h
e
e
o
a r a
s c
s
♦ After installation, apply corrosion protection (wax) all over
c
e
l e
n p
u t
gearbox e dcrossmember. a
n
t
y
t
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m
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Bolts for gearbox carrier on lad‐ 50 Nm +90°
p
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gearbox
p
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mounting 1) o
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Bolts
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for gearbox mounting on 50 Nm +90° t
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gearbox
o
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1) Renew.
p
l n
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s
a d
v
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.
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p
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.
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h
g
i
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c y
b w k
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. G
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P
36
n AG
. Volksw age n AG
w a g e d oe

l k s s n
y V
o o t
g u
d b
e
a r
a n
i s
o
h
r Amarok 2011 ➤ t e
e
t
u o
s
a 8-speed automatic gearbox 0CM -c c Edition 04.2013 r
a
s
e
l e
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l s
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w
c
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♦ Workshop hoist - a VAS 6100-
t
r
c
o
p r
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n
i e
, c
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p s
r o
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♦ Lifting tackle - 2024 A- h
g i
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b
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. G
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A
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t o g
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P
– Attach lifting tackle - 2024 A- as follows to lifting eyes of gear‐

box and transport using workshop hoist - VAS 6100- .
Input shaft side:

4th hole of hook rail in position 1 of lifting tackle -arrow A-.
Output shaft side:
First hole of hook rail in position 7 of lifting tackle -arrow B-.
37
Amarok 2011 ➤
e n A
G . Volksw age n AG
w a g d oe

l k s s n
V o
y
o t
g u
d b
e
a r
a n
i s
r t
o e
h
t
e
u o
a r
a
s c
s c
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n p
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d
a
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o
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c
t
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o
r
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h
t
e
r
c
a o
p r
r
n
i e
, c
s
❑ e
Removing and installing
s
t
n
e
⇒ page 39
o
p
s
s
r o
u f
p
l n
i
a
i
f
o
r
c
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a
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❑ Insert
to stop by hand o n
c n
i
with new O-ring. r
o t
h
e
t i
s
❑ Moisten a O-rings with d
v
i o
c
ATF. p
r
r
u
m
o
f e
n
❑ Removing g and
n
i installing t
.
C
o
y
⇒ page 42 p o
C p
r y
. t
h i
g
g i
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h
V
y t
p y
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s
a
❑ Renew after removal
d
e
. G
e
A
n
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c
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t o g
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P
❑ Moisten O-ring with ATF
❑ 20 Nm
❑ 8 Nm
❑ Insert to stop by hand

with new O-ring.
❑ Moisten O-rings with
ATF.
⇒ page 45
❑ 8.5 Nm
38
Amarok 2011 ➤
❑ 8 Nm
❑ 7 Nm
❑ Insert to stop by hand with new O-ring.

❑ Moisten O-rings with ATF.
❑ Removing and installing ⇒ page 42
❑ 2 Nm
♦ Engine bung set - VAS 6122-
n AG
. Volksw age n AG
w a g e d oe

l k s s n
y V
o o t
g u
d b
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a r
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a
s c
s c
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n p
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a
♦ Drip tray - V.A.G 1306- d n
e
t
y
t
i l
i
m
a
r b
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l
i
p t
t
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o
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s
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c
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m t
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t
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r
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.
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p
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.
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g i
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b
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V
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c
y
b w k
s
d a
e
. G
e
A
n
t
c
e
t o g
r
P
39
Amarok 2011 ➤
♦ Comply with rules for cleanliness when working on gearbox

⇒ page 6 .
♦ Observe repair instructions ⇒ page 1 .
♦ Observe safety precautions ⇒ page 4 .
♦ Seal open lines and connections using clean plugs from en‐
gine bung set - VAS 6122- .
– Remove front bumper cover ⇒ General body repairs, exterior;

Rep. gr. 63 ; Front bumper; Removing and installing front
bumper cover .
– Unscrew bolts -arrows- and remove front struts -1-.
n AG
. Volksw age n AG
w a g e d o e
l k s s n
y V
o o t
g u
d b
e
a r
a n
i s
r t
o e
h
t
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u o
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a
s c
s c
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n p
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a
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t
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p
t
t
y
o
w
n i
t
s
h
i
,
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l s
o p
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w
– Lever off clips -arrows- and remove left air duct -1-.
c
t
n i
t
o
r
o
t
– Place dip tray - V.A.G 1306- under ATF cooler.

h
t
e
r
c
a o
p r
r
n
i e
, c
s t
e n
s e
o s
p s
r o
u f
p
l n
i
a
i
f
o
r
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a
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i
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c i
n
r
o t
h
e
t i
s
a d
v
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c
r
p
r
u
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o
f e
– Unscrew right bolt -arrow- and disconnect ATF line -1-
gfrom n
t
.
C
n
i
ATF cooler -2-. o
y
p
o p
C .
t r y
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h
g i
g
b
r h
V
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p y
l o
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c
y
b w k
s
d a
e
. G
e
A
n
t
c
e
t o g
r
P
40
Amarok 2011 ➤
– Unscrew left bolt -arrow- and disconnect ATF line -1- from ATF
cooler -2-.
n AG
. Volksw age n AG
w a g e d oe

l k s s n
y V o o t
g u
d b
e
a r
a n
i s
r t
o e
h
t
e
u o
a r
a
s c
s c
e
l e
n p
u t
a
d n
e
t
y
– Unscrew
i
m
bolt -arrow- from ATF cooler -1-.
t l
i
a
r b
e i
l
i
p t
t
y
o
w
n i
t
s
h
i
,
r
e
e
l s
o p
h e
w
c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p r
r
n
i e
, c
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e n
s e
o s
p s
r o
u f
p
l n
i
a
i
f
o
c
r
r
m
– e
Unclip ATF cooler -2- from guide -arrow- on radiator -1-.
m
a
t
i
o
m n
o
c
r
n
i
o t
h
e
t i
s
a d
v
i o
c
r
p
r
u
m
o
f e
g n
t
.
C
n i
o
y
p
o
C y p
r
.
t
h i
g
g i
r b
h
V y
y t
p
l o
o
c k
s
w
y
b
d a
e
.
e
A
n
t
G
c
e
t o g
r
P
41
Amarok 2011 ➤
– Pull ATF cooler -arrow- upwards out of guide -1- and remove
ATF cooler.
♦ Seals must always be renewed.

♦ Moisten seals with ATF prior to installation.
– Install front bumper cover ⇒ General body repairs, exterior;

Rep. gr. 63 ; Front bumper; Removing and installing front
bumper cover .
– Checking ATF level and topping up ⇒ page 51
♦ ⇒ “5.1 Assembly overview - ATF circuit”, page 38

♦ Front bumper, Assembly overview - front bumper ⇒ Front
bumper; Rep. gr. 63 ; Assembly overview - front bumper cov‐
er .
e n A
G . Volksw age n AG
w a g d oe

l k s s n
y V
o o t
g u
d b
e
a r
a n
i s
r t
o e
h
t
e
u o
a r
a
s c
s c
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l e
n p
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d
a
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e
t
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i
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a
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l
i
p t
t
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o
w
n i
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s
h
i
,
r
e
e
l s
o
♦ Drip tray - V.A.G 1306-
p
h e
w
c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p r
r
n
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c
s t
e n
s e
o s
p s
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p
l n
i
a
i
f
o
r
c
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e
a
m t
i
m o
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c
r
n
i
o t
h
e
t i
s
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v
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c
r
p
r
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f e
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t
.
C
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p
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C
.
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V
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o
c k
s
w
y
b
d a
e
. G
e
A
n
t
c
e
t o g
r
P
42
Amarok 2011 ➤
G. Volksw age n AG
w a
g e n A d oe

l k s s n
y V
o o t
g u
d b
e
a r
a n
i s
r t
o e
h
t
e
u o
a r
a
s c
s c
e
l e
n p
u t
a
d n
e
t
y
t
i l
i
m
a
r b
e i
l
i
p t
t
y
o
w
n i
t
Seal open lines and connections s
using clean plugs from engine
i
,
h
r
e
e
bung set - VAS 6122- . o
l s
p
h e
w
c
t
n t
– Remove front bumper cover ⇒ General body repairs, exterior;

i o
r
o
t
h
e
Rep. gr. 63 ; Front bumper;
r
a
Removing and installing front
t
c
o
bumper cover . p
n
r
r
i e
, c
s
– If fitted, remove engine/gearbox
e
s
guard ⇒ General body re‐ t
n
e
pairs, exterior; Rep. gr.
o 66 ; Engine/gearbox guard; Removing
p
s
s
o
and installing engine/gearbox
u
p
guard .
r
f
l n
i
a f
o
– Place drip tray - V.A.G
c1306- underneath.
r
i
r
m
e
a
m
– Remove connecting hose mbetween charge air cooler and pres‐
t
i
o
n
o
sure pipe. c
r
n
i
o t
h
e
t i
s
– Unscrew bolts -arrows- and remove front struts -1-. a
v
i
d
o
c
r
p
r
u
m
o
f e
g n
t
.
C
n
i
o
y
p
o p
C
.
t r y
i
h
g g
i
r b
h
V
y t
p y
l o
o
c k
s
w
y
b
d a
e
. G
e
A
n
t
c
e
t o g
r
P
– Lever off clips -arrows- and remove left air duct -1-.
43
Amarok 2011 ➤
– Unscrew bolt -arrow- and pull supply and return lines out of
thermostat.
n AG
. Volksw age n AG
w a g e d oe

– Unscrew bolt -arrow- of return line -1-. l k s s n
y V
o o t
g u
d b
e
a r
a n
i s
r t
o e
h
t
e
u o
a r
a
s c
s c
e
l e
n p
u t
a
d n
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t
y
t
i l
i
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a
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l
i
p t
t
y
o
w
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t
s
h
i
,
r
e
e
l s
o p
h e
w
c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p
– Unscrew bolt -arrow- of supply line
i , -1-.
r
r
n e
c
s t
e n
s e
o s
p s
r o
u f
p
l n
i
a
i
f
o
c
r
r
m
e
a
m t
i
m o
o n
c
r
n
i
o t
h
e
t i
s
a d
v
i o
c
r
p
r
u
m
o
f e
g n
t
.
C
n i
o
y
p
o p
C
.
t r y
i
h
g g
i
r b
h
V
y t
p y
l o
o
c
y
b w k
s
d a
e
. G
e
A
n
t
c
e
t o g
r
P
44
Amarok 2011 ➤
– Unscrew bolts -arrows- from bracket and remove lines -1-.
♦ Seals must always be renewed.

♦ Moisten seals with ATF prior to installation.
e n A
G . Volksw age n AG
w a
g d oe
– Checking ATF level and topping up ⇒ page 51
l k s

s n
y V
o o t
g u
d b a r
– Install front bumper cover ⇒ General rbody e
i s repairs, exterior; a n
t
o e
Rep. gr. 63 ; Front bumper; Removing h
t
u and installing front e
o
a r
a
bumper cover . s
s
e
c
c
l e
n p
u t
a
– If fitted, install engine/gearbox dguard
e
t
⇒ General body repairs, n
y
t
exterior; Rep. gr. 66 ; Engine/gearbox
i
m guard; Removing and l
i
a
r b
e
installing engine/gearbox p
guard . i
l
i
t
t
y
o
w
n i
t
s
h
i
,
r
e
e
l
♦ ⇒ “5.1 Assembly overview - ATF circuit”, page 38
s
o p
h e
w
c
t
n
♦ Front bumper, Assembly overview - front bumper ⇒ Front
i
r
t
o
bumper; Rep. gr. 63 ; oAssembly overview - front bumper cov‐

t
h
t
e
r
c
er . a
p
o
r
r
n
i e
, c
s t
e n
s e
o s
p s
r o
u f
p
l n
i
a
i
f
o
r
c
r m
e
a
m t
i
o
m
o n
c i
n
r
o t
h
e
t i
s
a d
v
i o
c
r
p
r
u
m
o
f e
g n
t
.
C
n
i
o
y
p
o p
C
.
t r y
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h
g
i
g
b
r h
V y
y t
p
l o
o
c k
s
w
y
b
d
e a
. G
e
A
n
t
c
e
t o g
r
P
45
Amarok 2011 ➤
♦ Drip tray - V.A.G 1306-
e n A
G . Volksw age n AG
a g
w d oe

l k s s n
y V
o o t
g u
d b
e
a r
a n
i s
r t
o e
h
t
e
u o
a r
a
s c
s c
e
l e
♦ Torque wrench - u
V.A.G
n 1331- p
t
a
d n
e
t
y
t
i l
i
m
a
r b
e i
l
i
p t
t
y
o
w
n i
t
s
h
i
,
r
e
e
l s
o p
h e
w
c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p r
r
n
i , e
c
s t
e n
s e
o s
p s
r o
u f
p
l n
i
a
i
f
o
c
r m r
e
a
m t
i
m o
o n
c i
n
r
o t
h
e
t i
s
a d
o
Seal open lines and connections using clean plugs from engine v
i
r c
u
bung set - VAS 6122-
p
m
f.
r
o e
g n
t
.
C
n
i
o
y
p
o
– If fitted, remove engine/gearbox guard ⇒ General body re‐
p
C
.
t r y
i
h
g g
pairs, exterior; Rep. gr. 66 y ; p
i Engine/gearbox guard; Removing V y b
r h
t
and installing engine/gearbox c guard . l o
o
y
b w k
s
d
e a
. G
e
A
n
t
c
e
t o g
r
P
– Place drip tray - V.A.G 1306- underneath.
– Unscrew bolt -arrow- of ATF double line -1- from thermostat.
46
Amarok 2011 ➤
– Unscrew bolt -1- of ATF double line -arrows- and pull ATF
double line out of gearbox.
– Unscrew bolt -arrow- of ATF double line -1- from gearbox.
– Unscrew bolt securing ATF double line -1- from bracket -2- and
remove line together with clamp -arrow-. . Volksw age n AG
n AG
w a g e d oe

l k s s n
V o
y
o t
g u
e d b a r
a n
i s
h
r
o
t
e
e
t
u o
a r
a
s c
s c
e
l e
n p
u t
a
d n
e
t
y
t
i l
i
m
a
r b
♦ Seals must always be renewed. e i
l
i
p t
t
y
o
w
n i
♦ Moisten seals with ATF prior to installation. s
i
,
t
h
r
e
e
l s
o p
h e
w
c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p r
r
n
i e
, c
s t
e n
s e
o s
p s
r o
u f
– Checking ATF level and topping up p
⇒ page 51 l n
i
a
i
f
o
r
– If fitted, install engine/gearbox guard r
⇒
c
m
e General body repairs,
a
exterior; Rep. gr. 66 ; Engine/gearbox m guard; Removing and
m
t
i
o
n
installing engine/gearbox guard . o
c
r
i
n
t
o h
e
t i
s
a d
v
i o
c
r
p u
m
♦ ⇒ “5.1 Assembly overview - ATF circuit”, page
f 38
o
r
e
g n
t
.
C
n
i
o
y
p
o
C y p
r
.
t
h i
g
g
i
r b
h
V y
y t
p
l o
o
c k
s
w
y
b
d
e a
.
e
A
n
t
G
c
e
t o g
r
P
47
Amarok 2011 ➤
♦ Used oil collection and extraction unit - V.A.G 1782-
n AG
. Volksw age n AG
w a g e d o e
l k s s n
V o
y
o t
g u
d b
e
a r
a n
i s
r t
o e
h
t
e
u o
♦ Comply with a
s rules for cleanliness when working on gearbox
r
a c
s c
⇒ page 6 n l. e e
p
u t
d
a
n
e
t
y
i t l
i
m
a
r b
e i
l
i
p
t
t
y
– Position
o
n
used oil collection and extraction unit - V.A.G 1782- w
i
t
under gearbox.
s i
,
h
r
e
e
l s
o
– Remove ATF sump ⇒ page 58 .
p
h e
w
c
t
n t
– oCarefully pull ATF filter -arrow- downwards in

i o
r t
h
e
-direction of arrow- off mechatronic unit -1-.
t
r
a
c
o
p r
r
n
i e
, c
s t
e n
e
Install
o in reverse order of removal, observing the following:
s
s
s
p
r o
u f
p
l n
i
a
i
f
o
r
c
r m
e
a
m t
i
m o
o n
c i
n
r
o t
h
e
t i
s
a d
v
i o
c
r
p
r
u
m
o
f e
g n
t
.
C
n
i
– Fit O-ring -2- pon ATF-Filter -1-.
o
y
o
p
C
.
t r y
i
h
g i
g
b
r h
V y
y t
p
l o
o
c
y
b w k
s
d
e a
. G
e
A
n
t
c
e g
t o
r
P
On version A the solenoids are bonded in.
48
Amarok 2011 ➤
– Clean both solenoids -arrows-. Ensure solenoids are properly

seated with entire surface in recesses on ATF filter.
n AG
. Volksw age n AG
w a g e d oe

l k s s n
V o
y
o t
g u
d b
e
a r
a n
i s
r t
o e
h
t
e
u o
a r
a
s c
s c
e
l e
n p
u t
a
d n
e
t
y
t
i l
i
m
a
r b
e i
l
i
p t
t
y
– Clean both o solenoids -arrows-. The solenoids must be firmly
n
w
i
seated in
s guide.
t
h
i
,
r
e
e
l s
o p
h e
w
c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p r
r
n
i e
, c
s t
e n
s e
o s
p s
r o
u f
p
l n
i
a
i
f
o
r
c
r m
e
a
m t
i
m o
o n
i
n
– Fit ATF filter to mechatronic unit. c
r
o t
h
e
t i
s
d
♦ The suction acollar -1- of ATF filter must be inserted to stop into
v
i c
o
r
u
opening -2- of p
mechatronic unit.
r
o
f
m
e
g n
t
.
C
n
♦ Mounting -4- on the
p backside must engage in bolt -3- of me‐
o
i
y
o
chatronic unit.
p
C .
t r y
i
h g
i
g
b
r h
V y
y t
– Install ATF sump ⇒ page o
58 .
p
c
s l o
k
w
y
b
d
e a
. G
e
A
n
t
c
e g
t o
– Fill ATF ⇒ page 53 .
r
P
♦ ⇒ “1.1 Assembly overview - sump/oil strainer”, page 57
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
10 bar).
– Thoroughly clean area around unions for gearbox to ATF line,

ATF line to thermostat and ATF line to ATF cooler.
49
Amarok 2011 ➤
– 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 39 .
– Remove ATF lines -arrows- 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.
n AG
. Volksw age n AG
– Push hose onto other ATF line and repeat procedure. w a g e d o e
l k s s n
y V
o o t
g u
– Moisten O-ring with ATF. d b
e
a r
a n
i s
r t
o e
h
t
e
u o
– Install ATF pipes ⇒ page 42 . a
s
r
a
c
s c
e
l e
n p
– Install ATF cooler ⇒ page 39 . u
d
t
a
n
e
t
y
t
i l
i
m
a
r b
e i
l
i
t
p t
y
♦ ⇒ “5.1 Assembly overview - ATF circuit”, page o 38
n
w
i
t
s
h
i
,
r
e
e
l s
o p
h e
w
c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p r
r
n
i , e
c
s t
e n
s e
o s
p s
r o
u f
p
l n
i
a
i
f
o
r
c
r m
e
a
m t
i
m o
o n
c
r
n
i
o t
h
e
t i
s
a d
v
i o
c
r
p
r
u
m
o
f e
g n
t
.
C
n
i
o
y
p
o p
C
.
t r y
i
h
g i
g
b
r h
V
y t
p y
l o
o
c
y
b w k
s
d a
e
. G
e
A
n
t
c
e
t o g
r
P
50
Amarok 2011 ➤
♦ ATF filling unit - V.A.G 1924-
n AG
. Volksw age n AG
a g e
w d oe

l k s s n
y V
o o t
g u
d b
e
a r
a n
i s
r t
o e
h
t
e
u o
a r
a
s c
s c
e
l e
n p
u t
a
d n
e
t
y
t
i l
i
m
a
r b
e i
l
i
p t
t
y
o
w
n i
t
s
h
i
,
r
e
e
♦ Used
l
o
oil collection and extraction unit - V.A.G 1782- s
p
h e
w
c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p r
r
n
i , e
c
s t
e n
s e
o s
p s
r o
u f
p
l n
i
a
i
f
o
r
c
r m
e
a
m t
i
m o
o n
c i
n
r
o t
h
e
t i
s
a d
v
i o
c
♦ Vehicle diagnostic tester
r
p
r
u
m
o f e
g n
t
.
C
n
i
o
y
p
o p
C
.
t r y
i
The ATF level i
r must checked
at a certain temperature with the b t
h
g h g
y
engine running. The ATF p temperature is read on the ⇒ Vehicle V y
o
l
o
c k
s
w
y
b
a
diagnostic tester. When test temperature d
e
t
c
e
t o
r has been
. reached,
A
G
e
n g un‐
screw plug for ATF inspection/filler hole located above sump.
P

pairs, exterior; Rep. gr. 66 ; Engine/gearbox guard; Removing
• Gearbox must not be in emergency running mode.

• Vehicle must be standing absolutely level.
• Gearbox is set to position “P”.
51
Amarok 2011 ➤
• Extraction hose/extraction hoses of a switched-on exhaust

gas extraction system is/are connected.
• Heating and air conditioning system are switched off.
• ⇒ Vehicle diagnostic tester is connected.
• The ATF temperature should be between 30 ℃ and 35 ℃ at
the start of the test. If this temperature is exceeded, the gear‐
box first must cool off.
♦ The ATF temperature is read on ⇒ Vehicle diagnostic tester.

G. Volksw age n
♦ The further procedure is described in k sthe g e n A AG d
w a ⇒ Vehicle diagnostic
oe

l s n
tester. V
y
o o t
g u
b
e d
a r a
r i s n t
by o the ATF temperature.
♦ The ATF level is affected t h e
e
u o
a r
a
s c
s
♦ Checking the ATF level n
when the ATF temperature is too low e
l
c
e
p
leads to overfilling. d u t
a
n
e
t
y
t
i l
i
mlevel when the ATF temperature is too high
a
♦ Checking the ATF r b
e i
l
leads to underfilling.
i
p t
t
y
o
w
n i
t
♦ Both an excessive s
and an insufficient ATF level affects the
h
i
,
r
e
e
function of the o gearbox.
l s
p
h e
w
c
♦ The ATF level

n is checked on the ATF inspection/filler hole.
i
t
t
o
r
o
t
h
e
♦ The ATF level is correct if ATF is slightly dripping out of ATF
t
r
a
c
o
inspection/filler
p
n
hole at an ATF temperature of 35 °C to 45 °C r
r
e
(50 °C for hot
i ,
s
climate countries), due to the increased ATF c
t
n
level at higher
e
stemperatures. e
s
o
p s
o
♦ Renew plug u
for ATF inspection/filler hole.
p
r
f
l n
i
a
i
f
o
r
c
r m
e
a
m t
i
m o
o n
c i
n
r
t
o h
e
t i
s
a d
v
i o
c
r
p
r
u
m
o
f e
g n
t
.
C
n
i
o
y
p
o p
C
.
t r y
i
h
g
i
g
b
r h
V
y t
p y
l o
o
c y
b w k
s
d a
e
. G
e
A
n
t
c
e
t o g
r
P
– With engine running at idling speed, remove plug for ATF in‐
spection/filler hole -2- located above sump.
52
Amarok 2011 ➤
– Always renew plug and seal -arrow-.
ATF does not need topping up.

– Wait until ATF reaches a temperature of 45 °C and tighten G. Volksw age n AG
w a
g e n A new d o e

l k s s n
plug for ATF inspection/filler hole. This concludes V o
y
the ATF o t
g u
b
d
check. s
i
e
a r
a n
r t
o e
h
t
e
u o
a r
a c
s
s c
e
l e
– ATF must be replenished. n p
u t
d
a
n
e
t
y
t
i l
– Shake oil bottle before opening.
m
r
i
a
b
e i
l
i
p t
– With engine »running«, insert t
filling hook of ATF filling unit -
y
o
w
n i
V.A.G 1924- into ATF inspection/filler
s hole. i
t
h
,
r
e
e
l s
o p
h
– Fill with ATF using ATF wfilling unit - V.A.G 1924- -arrow- until
e
c
t
n
ATF flows out of ATF inspection/filler hole.
t
i o
r
o
t
h
t
e
r
c
a o
p r
r
n
i , e
c
s t
e
n
s e
o s
p s
r o
u f
p
l n i
a
i
f
o
r
c
r m
e
a
– Wait until an ATF m
temperature of 45 °C is reached. t
i
m o
o n
c i
n
– Tighten new plug. r
o t
h
e
t i
s
a d
v
i o
c
r
p
r
u
m
o
f e
g n
t
.
C
n i
o
y
p
o p
C
.
t r y
i
h
g i
g
b
r h
V
y t
p y
l o
o
c k
s
w
y
b
d a
e
. G
e
A
n
t
c
e
t o g
r
P
– While the engine is running,
– wait until an ATF temperature of 90 ℃ is reached.
– Now ensure that this temperature is maintained for 5 minutes,
while the ATF cooler is filled.
– Stop engine and let ATF cool off to a temperature of 35 °C.
– Then check ATF level again.
– If fitted, install engine/gearbox guard ⇒ General body repairs,
exterior; Rep. gr. 66 ; Engine/gearbox guard; Removing and
installing engine/gearbox guard .
ATF inspection plug 35 Nm
53
Amarok 2011
2011 ➤
♦ ATF fillin
filling
g unit
unit - V.A.G
V.A.G 192
1924-
4-
♦ Used oil
oil collectio
collection
n and extrac
extraction
tion unit
unit - V.A.G 1782-
1782-
n AG
. Volksw age n
n AG
w a g e d o
oe

l k s s n
y V
o o t
g u
d b a r
♦ Vehicl
Vehicle
e diagn
diagnost
ostic
ic teste
tester
r e
i s
r
a n
t
o e
h
t
e
u o
a r
a
s c
s c
e
l e
n p
u t
a
d n
e
t
y
t
i l
i
m
a
r b
e i
l
i
p t
t
y
o
w
n i
t
s
h
i
,
r
e
e
l s
o p
h e
w
c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p
♦ Eng
Engine
ine off.
ff. n
i , e
r
r
c
s t
n
♦ Vehicle level, all supports in lifting
e
platform at same height.
s e
s
o
p s
o
♦ If noise
noise insulatio
insulation
n tray is presen
present, t, it must be remo
r
u
p
removed
ved f
l n i
a f
o
♦ Select
Selector
or lever
lever in “P”.
“P”. i
c
r
r
m
e
a
♦ ⇒ Vehicle
Vehicle diagn
diagnostic
ostic tester co m
tester is conne
nnected.
m cted.
t
i
o
n
o
c i
n
r
♦ At start
start of work,
work, ATF temper
temperatur
ature
e must not
not be above
above 45 ℃.
℃. o t
h
i
e t s
a d
v
i o
c
r
p
r
u
m
o
f e
g n
t
.
C
n
i
o
y
p
o p
C r y
If ATF temperature is above 45 °C, let the gearbox .
t
h cool
g i off. i
g
b
r h
V
y t
p y
l o
o
c
y
b w k
s
d a
e
. G
e
A
n
t
c
e
t o g
r
P
54
Amarok 2011
2011 ➤
♦ Observe regulations for disposal.

♦ Renew ATF drain plug and seal.
♦ Renew plug for ATF inspection/filler hole.
– Position used
used oil collection and extraction
extraction unit - V.A.G 1782-
1782-
under gearbox.
– Remove ATF drain plug -1- from sump.
sump.
– Drain ATF.
• Tighte
Tighten
n ATF
ATF drain
drain plug
plug in
in sump
sump..
n AG
. Volksw age n
n AG
w a g e d o
oe

l k s s n
y V o o t
g u
d b
e
a r
a n
i s
r t
o e
h
t
e
u o
a r
a
s c
s c
e
l e
n p
u t
d
a
n
e
t
y
t
i l
i
m
a
r b
e i
l
i
p t
t
y
o
w
n i
t
s
h
i
,
r
e
e
l s
o p
h e
w
c
t
n
i
t
o
r
– Unscrew plug for ATF inspection/filler hole -2- and insert filling
o
t
h
t
e
r
hook p aof

ATF filling unit - V.A.G 1924- into ATF inspection/filler c
o
hole. i ,
r
r
n e
c
s t
n
– With e
engine stopped, fill ATF
s
o
ATF up to overflow
overflow edge using
using ATF e
s
filling p
unit - V.A.G 1924- .
r o
s
u f
p
l n
i
a
i
f
o
r
c
r m
e
a
m t
i
m o
o n
c
r
n
i
o t
h
e
t i
s
a d
v
i o
c
r
p
r
u
m
o
f e
g n
t
.
C
n
i
o
y
p
o
C y p
r
.
t
h i
g
g i
r b
h
V
y t
p y
l o
o
c y
b w k
s
d a
e
. G
e
A
n
t
c
e
t o g
r
P
Amarok 2011
2011 ➤
– Start engine
engine and immediately
immediately fill more ATF until it flows out of
overflow edge -arrow-.
– Screw in plug for ATF inspection/filler
inspection/filler hole AG. Volksw age n
hole hand-tight.
hand-ti nght. n AG
a g e d o
o w e s
l k s n
y V
o o t
– Run engine
engine at idling speed.
speed. d b
g u
a r
e a n
i s
r t
o e
– With brake pressed,
pressed, shift through
through h
u all selector
selector lever positions
positions e
t o
a r
a
at idling speed and make sure e seach s position is engaged for at c
c
l e
least 10 seconds. n
u
p
t
a
d n
e
t
y
t
– Move selector
selector lever to “P”
m position.
i l
i
a
r b
e i
l
i
p t
– Keep constant
constant engine ospeed
sp
t eed of 2000
2000 rpm for 30
30 seconds to y
w
n
allow torque converter s to be filled. i
i
t
h
,
r
e
e
l
– Finally, check ATF
ATF level and top up ⇒ page 51 .
51 .
s
o p
h e
w
c
t
n
i
t
o
r
o
t
h
t
e
♦ ⇒ “1.1 Assembly overview
a - sump/oil strainer”, page 57
r
c
o
p r
r
n
i e
, c
s t
e n
s e
s
ATF inspection
inspection plug
o
p
r
35 Nm o
s
u f
p
l n
i
a
i
f
o
r
c
r m
e
a
m t
i
m o
o n
c i
n
r
o t
h
e
t i
s
a d
v
i o
c
r
p
r
u
m
o
f e
g n
t
.
C
n
i
o
y
p
o p
C
.
t r y
i
h
g i
g
b
r h
V
y t
p y
l o
o
c k
s
w
y
b
d a
e
. G
e
A
n
t
c
e
t o g
r
P
56
Amarok 2011 ➤

⇒ page 62 .

❑ Observe tightening se‐
quence ⇒ page 65
❑ 8 Nm n AG
. Volksw age n AG
a g e d o e w
l k s s n
y V
o o t
g u
d b
e
a r
a n
i s
r t
o
❑ Renew hafter removal
t
u
e
e
o
a r
a
s c
s c
e
l e
n p
u t
d
a
n
e
t
y
t
i l
i
m
a
r b
❑ e Removing
i
p
t
and installing l
i
t
y
o
⇒ page 60
w
n i
t
s
h
i
,
r
e
e
l s
o p
h e
w ❑ Renew after removal c
t
n
i
t
o
r
o ❑ 8 Nm t
h
e
t
r
c
a o
p r
r
n
i e
,
s
e
❑ Renew after removal c
t
n
s e
o s
p s
r o
u f
p
l
a
❑ Removing and installing n
i
f
o
i
c
r
⇒ page 47 m r
e
a
m t
i
m o
o n
c i n
❑ Ensure solenoids are
r
o t
h
t properly seated on ATF
e i
s
a d
o
rfilter with their entire sur‐
v
i c
u
p
m
face.
r
o
f
g
e
n
t
.
C
n
i
❑ Clean y prior to installa‐
p
o o
tion. C
p
.
t r y
i
h
g
i
g
b
r h
V y
y t
❑ Not available p as a
o
c re‐ l o
k
y s
w
placement part anymore. Cannot be G
separated from ⇒ Item 7 (page 57) .
b
d a
e
. A n
e
t
c g
e
t o
r
P

❑ 12 Nm
❑ 12 Nm
Amarok 2011 ➤
G. Volksw age n AG
g e n A d w a o e
l k s s n
y V
o o t
g u
d b
e
a r
a n
i s
r t
o
h
t
u
⇒ page 58 e
e
o
a r
a
s c
s c
e
l e
n p
u t
d removal
a
❑ Renew t t e after n
y
l
i i
mtightening sequence ⇒ page 65
a
❑ Observe r b
e i
l
i
p t
t
y
❑ 8 Nm n o w
i
t
s
h
i
,
r
e
e
l s
o p
h
e
w
c
t
n t
❑ ATF pump intake

i o
r
o
t
h
t
e
r
c
a o
p r
r
n e
i , c
s t
e n
e
❑ Oil osupply for ATF pump
s
s
s
p
r o
u f
p
l n
i
a
i
f
o
r
c
r m
e
a
m t
i
m o
o n
c i
n
r
o t
h
e
t i
s
♦ Used oil collection
a and extraction unit - V.A.G 1782- d
v
i o
c
r
p
r
u
m
o
f e
g n
t
.
C
n
i
o
y
p
o
C y p
r
.
t
h i
g
g i
r b
h
V
y t
p y
l o
o
c k
s
w
y
b
d
e a
. G
e
A
n
t
c
e
t o g
r
P

pairs, exterior; Rep. gr. 66 ; Engine/gearbox guard; Removing
– Position used oil collection and extraction unit - V.A.G 1782-
under gearbox.
– Unscrew ATF drain plug and drain ATF ⇒ page 53 .
58
Amarok 2011 ➤
Support gearbox using engine and gearbox jack - V.A.G 1383 A-
ensuring that sump can still be removed in the following work
procedure.
– Position engine and gearbox jack - V.A.G 1383 A- under trans‐

fer box.
– Unscrew bolts -arrows- of sump -1-.
G. Volksw age n AG
– Remove sump -1- downwards in -direction l k sof g e n A
arrow-.
w a d o e
s n
y V
o o t
g u
d b
e
a r
a n
i s
r t
o e
h
t
e
u o
Install in reverse order of removal,
s
observing the following: a r
a c
s c
e
l e
n p
u t
d
a
n
e
t
y
t
i l
i
m
a
r b
e i
l
i
p
t
t
y
♦ Renew ATF sump bolts

n and gasket. o
w
i
t
s
h
i
,
r
♦ In case of high mileage vehicles it is recommended to renew

e
e
l s
o p
the ATF filter once h
the
w
ATF sump has been removed e
c
⇒ page 47 .
t
n
i
t
o
r
o
t
h
e
♦ Otherwise, the ATF filter must only be renewed when dam‐
t
r
a
c
o
aged. p
n e
r
r
i , c
s t
e
n
s e
o s
p s
r o
u f
p
l n
i
a
i
f
o
r
c
r m
e
a
m t
i
m o
o n
c i
n
r
o t
h
e
t i
s
a d
v
i o
c
r
p
r
u
m
o
f e
g n
t
.
C
n
i
o
y
p
o p
C
.
t r y
i
h
g i
g
b
r h
V
y t
p y
l o
o
c k
s
w
y
b
d
e a
. G
e
A
n
t
c
e g
t o
r
P
59
Amarok 2011 ➤
– Clean both solenoids -arrows-. Ensure solenoids are properly

seated with entire surface in recesses on ATF filter.
– Thoroughly clean sealing surface. Ensure that residues from
old gasket are removed completely.
– Ensure proper seating of ATF filter on mechatronic unit. Oth‐

erwise the ATF sump cannot be fitted properly.
♦ The suction collar -1- of ATF filter must be inserted to stop into
opening -2- of mechatronic unit.
♦ Mounting -4- on the backside must engage in bolt -3- of me‐
chatronic unit.
e n A
G . Volksw age n AG
a g
w d oe

l k s s n
y V
o o t
g u
d b
e
a r
a n
i s
r t
o e
h
t
e
u o
a r
a
s c
s c
e
l e
n p
u t
a
d
– Tighten e bolts in the specified sequence.
t
t
n
y
l
i i
m
a
r b
– e gearbox
Install crossmember with gearbox mounting. i
l
i
p t
t
y
o
w
– Fill s nATF ⇒ page 53 .
i
i
t
h
,
r
e
e
l s
o p
h e
w
c

t
n i
t
o
r
o
t
h
t
e
r
c
a o
p r
r
n
i e
, c
s t
e n
s e
o s
p s
r o
u f
p
l n
i
a
i
f
o
r
c
r m
e
a
m t
i
m o
o n
c i
n
r
o t
h
e
t i
s
a d
v
i o
c
r
p
r
u
m
o
f e
g n
t
.
C
n
i
o
y
p
o p
C
.
t r y
i
♦ The hydraulic impulse oil storage is not installed in all gear‐ h
g g
i
r b
h
V y
y t
p
boxes. o
c y
b s
w
o
l
k
d a
e
.
e
A
n
t
G
c
e
t o g
♦ Rules for cleanliness ⇒ page 6 .
r
P
60
Amarok 2011 ➤
• Gearbox is installed.
– Shift selector lever to position “P”.
– Switch off ignition and remove ignition key.

– Remove ATF filter ⇒ page 47 .
– Carefully disconnect connector -arrow- from hydraulic impulse

oil storage -1-.
e n A
. Volksw age n AG
G
w a g d oe

l k s s n
y V
o o t
g u
d b
e
a r
a n
i s
r t
o e
h
t
e
u o
a r
a
s c
s c
e
l e
n p
u t
a
d n
e
t
y
t
i l
i
m
a
r b
e i
l
i
p t
t
y
o
w
n i
t
s
h
i
,
r
e
e
l s
o p
h e
w
c
– nUnscrew bolts -arrows- from hydraulic impulse oil storage

t
t
i o
r
o -1-.
t
h
t
e
r
c
a o
– i Remove hydraulic impulse oil storage.
p
n
r
e
r
, c
s t
e n
s e
o s
p s
r
u
o
f
p
l n
i
a
i
f
o
r
c
r m
e
a
m t
i
m o
o n
c
r
n
i
t
♦ Renew
e
t
O-ring and bolts for hydraulic impulse oil storage.
o h
i
s
a d
v o
♦ Ensure
r that connecter is properly engaged and secured.
i
p
r
c
u
m
o
f e
g n
t
.
C
n i
– Insert hydraulic
y
p
o impulse oil storage with new O-ring. o
p
C
.
t r y
i
h g
– Observe tightening
i
r
y
p sequence of bolts ⇒ page 65 . g b
V
y
h
t
l o
o c
y
b w k
s
a
– Connect connector to hydraulic P impulse oil storage.
d
e
. G
e
A
n g t
c
e
t
o
r
– Install ATF filter ⇒ page 47 .

– Install ATF sump ⇒ page 58 .
– Fill ATF ⇒ page 53 .
61
Amarok 2011 ➤
♦ Guide pin - T40199-
n AG
. Volksw age n AG
w a g e d o e
l k s s n
V o
y
o t
g u
d b
e
a r
a n
i s
r t
o e
h
t
e
u o
a r
a c
s
s c
e
l e
n p
u t
d
a
n
e
t
y
t
i l
i
m
a
r b
e i
l
i
p
t
t
y
o
w
n i
t
s
h
i
,
r
e
e
l s
o p
h e
w
c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p r
r
n
i e
, c
s t
e
n
s e
s
♦ Observe repair instructions
o
p ⇒ page 1 .
r o
s
u f
♦ Comply with rules for p

cleanliness ⇒ page 6 .
l
a i
n
i
f
o
r
c
r m
e
a
m t
i
m o
o n
c i
n
r
o t
h
e
t i
s
a d
v
i o
c
r
p
r
u
m
o
f e
g n
t
.
C
n
i
o
y
p
o p
C
.
t r y
i
• Gearbox is installed. h
g i
r b
g
h
V
y t
p y
l o
o
c k
s
– Shift selector lever to position “P”. w
y
b
d a
e
. G
e
A
n
t
c
e g
t o
r
P
– Switch off ignition and remove ignition key.
– Remove ATF filter ⇒ page 47 .
– Remove hydraulic impulse oil storage ⇒ page 60 .
62
Amarok 2011 ➤
– Unlock connector -arrow- by turning it anti-clockwise in

-direction of arrow-.
n AG
. Volksw age n AG
w a g e d o e
l k s s n
V o
y
o t
g u
d b
e
a r
a n
i s
r t
o e
h
t
e
u o
a r
a c
s
s c
e
l e
n p
u t
d
a
n
e
t
y
t
i l
i
m
a
r b
e i
l
i
p
t
t
y
o
w
n i
– Unscrew s bolt and pull catch -1- of connector downwards in
i
,
t
h
r
-direction
e of arrow-.
e
l s
o p
h e
w
c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p r
r
n
i e
, c
s t
e n
s e
o s
p s
r o
u f
p
l n
i
a
i
f
o
r
c
r m
e
a
m t
i
m o
o n
c i
n
r
o t
h
– Pull connector
e
t
a
housing -arrow- in -direction of arrow- out of d
i
s
gearbox v
-1-.
i
r
o
c
u
p
r m
o
f e
g n
t
.
C
n
i
o
y
p
o p
C
.
t r y
i
h
g i
g
b
r h
V y
y t
p
l o
o
c
y
b k
s
w
d a
e
. G
e
A
n
t
c
e
t o g
r
P
♦ Bolt -16- has already been removed during removal of con‐

nector housing.
♦ Do not yet remove bolt -1-.
63
Amarok 2011 ➤
– Unscrew bolts in sequence -18 through 2-. Pull out gearbox

output speed sender - G195- after bolt -17- has been loos‐
ened, in order to prevent the sender from being damaged.
– Screw in the 4 guide pins - T40199- hand-tight into holes
-2, 5, 13, 14-.
– Unscrew bolt -1-.
– Remove mechatronic unit downwards.

1 - Electronic module with sensors
2 - Electronic gearbox control
3 - Hydraulic valve body
4 - Solenoid valves
5 - Gearbox connector
Install in reverse order of removal, observing the following: n AG

. Volksw age n AG
w a g e d oe

l k s s n
y V
o o t
g u
e d b a r
a n
♦ Moisten seals with ATF before fitting. Do not i s use any other
r t
o e
h
t
e
lubricants. u
a
o
r
a
s c
s c
e
l e
♦ Always renew a valve body which is
u fouled or defective.
n p
t
a
d n
e
t
y
t
♦ Do not use fluffy cloths. i
m
l
i
a
r b
e i
l
i
p t
♦ Renew connecting piece with o
seals
t ⇒ Item 15 (page 58) . y
w
n i
t
s
h
♦ Renew seal for oil passage between e
gearbox and mechatronic
i
,
r
e
l
unit ⇒ Item 14 (page 58) . h o
s
p
e
w
c
t
n
i
t
o
r
o
t
h
t
e
r
c
a o
p r
r
i , n e
♦ Renew bolts for mechatronic
s unit.
e
c
t
n
s e
o s
♦ The guide pins - T40199- prevent
p the mechatronic unit from
r o
s
canting during installation. u

This
p ensures that the ATF lines on n
f
i
the backside of the mechatronic unit are not being damaged.

l
a i
f
o
r
c
r m
e
a
♦ Thus, the aid of a 2nd mechanic
m is recommended when in‐ t
i
o
stalling the mechatronic unit m
with
o
c
gearbox installed. n
i
n
r
t
o h
e
t i
s
a d
v
i o
c
r
p
r
u
m
o
f e
g n
t
.
C
n i
o
y
p
o p
C
.
t r y
i
h
g
i
g
b
r h
V
y t
p y
l o
o
c k
s
w
y
b
d a
e
. G
e
A
n
t
c
e
t o g
r
P
64

Amarok 8 Speed Automatic Gearbox

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Amarok 8 Speed Automatic Gearbox

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G.

6.1 Checking ATF level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

1.1 Assembly overview - sump/oil strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

2.1 Removing and installing mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

(VRL005441; Edition 04.2013)

A summary of the special tools and workshop equipment used in

♦ First thoroughly clean connecting points and surrounding

areas and o

tween the , engine and gearbox are correctly located.

vent soiling. p Use plastic sheeting and paper. Use lint-free

♦ Open side of noil seal faces oil.

You have probably at some time received an electrical shock

on the vehicle (bolts, nuts, washers e

♦ Connect and disconnect measuring and testing devices only

– Disconnect battery ⇒ Electrical components; Rep. gr. 27 .

– Disconnect battery ⇒ Electrical components; Rep. gr. 27 .

♦ Thoroughly clean all joints and surrounding areas before dis‐

Gearbox Identification NPZ NPY NLG NLF

Reverse 3.300 3.300 3.300 3.300

The ATF is obtainable as a spare part.

❑ Removing and installing

– Always secure converter.

Therefore, always work with care.

♦ Oil seal extractor lever - VW 681-

– Apply oil seal extractor lever - VW 681- directly behind sealing

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

– Extract ATF from torque converter using oil extractor -

– Extract ATF using waste oil collection and extraction unit -

– Push torque converter into gearbox to stop.

• The torque converter is correctly installed when the distance

The torque converter is properly installed when the gearbox can

❑ Renew after each re‐

• The starter must not operate in

selector lever is shifted to position

lever can be shifted into a driving e

• Selector lever is locked and cannot be shifted out of “P” posi‐

– Do not operate brake pedal.

– Shift selector lever into “Tiptronic gate”.

Simultaneous illumination of all selector lever position display

– Press emergency release lever downwards in

♦ Hose clip pliers - V.A.G 1275- n AG

– Remove clamp -arrow-.

Handle is removed together with selector cover.

• Selector lever is in position “D”. n

handle with the button pressed in. a

If not installed correctly, button remains inserted in handle after

– Secure clamp -arrow- with hose clip pliers - V.A.G 1275- .

♦ Removal lever - 80 - 200-

– Remove transfer box ⇒ Power transmission; Rep. gr. 39 ;

– Unclip selector lever frame -1- -arrows- and disconnect all

– Unscrew nuts -arrows- and remove selector mechanism

Install in reverse order of removal, observing the following:

Nuts of selector unit 8 Nm

tion). i , n e

– Carefully press selector lever ccable onto selector shaft lever.

Do not pull selector lever backwards or forwards when tightening

– Tighten bolt for selector lever cable.

Bolt for selector lever cable 12 Nm

♦ Removal lever - 80 - 200-

♦ Torque wrench - V.A.G 1331-

– Pull securing clip -arrow- in -direction of arrow- off selector

– Tie up propshaft -1- at a suitable location using wire -arrow-.

– Position engine and gearbox jack - V.A.G 1383 A- under trans‐