Transmission Speed Sensor: Service and Repair
Sensor Module with Transmission Input Speed Sensor (G612), (G632), (G676) and Circuit Board 3
Special tools, testers and auxiliary items required
• Counterhold Tool (T40217)
• Bit (T40228)
• Engine and Transmission Holder (VAS 6095)
• Lifting Eyebolt (3368)
• Adapter for VW Slide Hammer (VW 771/40)
• Engine Sling (2024 A)
• Guide Pins M8 (T10273)
• Sealant, refer to the Parts Catalog
• The transmission input speed sensor 2 (G612) , transmission input speed sensor 1 (G632) , drive position sensor (G676) and circuit board 3 are integrated in the sensor module. The components can only be replaced as a single sensor module unit.
• Replace the wiring set for the sensor module (- item 39 - => [ (Item 39) Wiring Set for Sensor Module ] DSG Transmission Mechatronic (J743) Overview) when replacing the sensor module.
Removing
• Secure the transmission to the (VAS 6095). Refer to => [ Securing on Engine and Transmission Holder ] Securing On Engine and Transmission Holder.
- Remove the flywheel. Refer to => [ Flywheel ] Flywheel.
- Remove the dual clutch. Refer to => [ Dual Clutch ] Dual Clutch.
- Remove DSG transmission Mechatronic (J743). Refer to => [ DSG Transmission Mechatronic (J743) ] DSG Transmission Mechatronic (J743).
- Remove the oil pump and the suction jet pump. Refer to => [ Oil Pump and Suction Jet Pump ] Service and Repair.
• The wiring set for the sensor module must be replaced when replacing the sensor module.
- Loosen the bolts - arrows - on the wiring set for the sensor module.
- Loosen the bolt - 1 -.
- Pull the fastener - arrow A - and remove the connector - arrow B - to disconnect the connector from the sensor module.
- Remove the wiring set for the sensor module.
- Mount the socket (T40228) on the connector housing, turn it all the way to the left - arrow A - and then remove the connector housing for the sensor module.
- Remove the connector housing for the sensor module - arrow B -.
- Remove the center differential housing and center differential. Refer to => [ Center Differential Housing and Center Differential, Bolted Driveshaft ] Center Differential Housing and Center Differential, Bolted Driveshaft or => [ Center Differential Housing and Center Differential, Attached Driveshaft ] Center Differential Housing and Center Differential, Attached Driveshaft.
- Remove the oil guide for the input shaft - arrow -.
- Loosen the twelve-point bolt - A - for the side shaft - B - on the pinion as follows:
- Mount a twelve-point socket - C - (21 mm) with an extension - D - over the twelve-point bolt - A -.
- Insert the (T40217) with the outer splines - arrow 1 - into the inner splines - arrow 2 - on the side shaft.
- Tighten (T40217) to the transmission intermediate housing - arrows -.
- Loosen the bolt on the side shaft.
• The bolt has a high loosening torque.
- Remove the bolt - 1 - and the side shaft - 2 -.
- Remove the spur gear - 1 - and needle bearing - 2 - from the output shaft - 3 -.
- Wrap the splines for the outer driveshaft with adhesive tape - arrow -, so that the inner surfaces of the suction jet pump are not damaged when removing or installing.
- Coat the tape lightly with grease.
- Adjust the transmission housing on the engine/transmission holder so that it is vertical.
• The clutch side faces down.
- Remove the bolts - arrows - all around the transmission intermediate housing.
- Hang the transmission intermediate housing - 1 - by the (VAS 6100) as illustrated.
There is the risk of an accident if the support bridge parts are loose.
• Install each threaded connection on the (3368) and (VW 771/40) to make sure they are secure.
• Secure the hooks and locking pins on the (2024 A) with cotter pins.
- Lift the transmission intermediate housing slowly and carefully off the transmission housing.
- Place the transmission intermediate housing on a workbench.
- Remove the bolt - arrow -, and then remove the sensor module - 2 -.
• The front oil catch tray - 1 - is engaged to the sensor module and will also be removed.
- Release the tabs to remove the front oil catch tray - 1 - from the sensor module.
Installing
• Tightening specifications, refer to => [ Transmission Overview ] Transmission Overview.
• Replace bolts that are tightened to the specification.
• There are different versions of the sensor module and screw, depending on the date of manufacture. Allocation, refer to the Parts Catalog
- Wrap the splines for the outer driveshaft with adhesive tape - arrow -, so that the inner surfaces of the suction jet pump are not damaged when installing.
- Coat the tape lightly with grease.
- Remove the shaft seal for the separator in the transmission housing starting from the transmission side with a screwdriver - arrow -.
• Both of the shaft seals for the separator in the transmission housing must be replaced since they will be damaged by the driveshaft when the transmission halves are pressed together.
- Insert the sensor module into the guide openings and tighten it - arrow -.
- Insert the front oil catch tray into the holes in the gear carrier and into the guide on the sensor module - arrows -.
• The oil catch tray must click into place.
Prepare the connector for the sensor module for installation:
• It is necessary to replace the O-ring on the connector - 2 - for the sensor module if the sensor module is not being replaced.
- Check whether the connector - 2 - is secured on the bracket - 1 - for the sensor module.
- Push the connector housing - 3 - onto the connector until it clicks into place. not turn it.
- Adjust the transmission housing on the engine/transmission holder so that it is vertical.
- Move the gearshift lever all the way in direction of travel - arrow -.
- Make sure the alignment sleeves - 1 and 2 - are installed inside the transmission housing.
- Coat the transmission housing flange - arrow - evenly and lightly with sealant. Refer to the Parts Catalog.
- Make sure the magnet - arrow - is installed inside the transmission housing.
- Insert the front final drive oil guide into the transmission housing.
• The oil guide must be inserted into the holes in the transmission housing at 3 locations - arrows -.
- Install the (T10273) into the threaded holes under the alignment sleeves.
- Hang the transmission intermediate housing - 1 - by the (VAS 6100) as illustrated.
There is the risk of an accident if the support bridge parts are loose.
• Install each threaded connection on the (3368) and (VW 771/40) to make sure they are secure.
• Secure the hooks and locking pins on the (2024 A) with cotter pins.
- Lower the transmission intermediate housing into the transmission housing slowly and carefully.
There is a danger of damaging the sensor module.
• When installing the transmission intermediate housing, pay close attention that the sensor module is not on the oil guide - 1 - and will not be damaged.
- When lowering the transmission intermediate housing, guide it without tilting it so that the connector - 1 - for the sensor module plunges into the opening - arrow - on the transmission housing.
• The procedure from the transmission intermediate housing side is shown. The procedure from the transmission housing side must also be performed.
- Guide the transmission intermediate housing onto the transmission housing and tighten it. Refer to => [ Transmission Intermediate Housing to Transmission Housing - Tightening Specification and Sequence ] Transmission Overview.
- Connect the (T40228) flush with the connector housing for the sensor module.
• The tabs for the (T40228) must securely mesh into the openings on the connector housing for the sensor module.
- Turn the connector housing with the (T40228) 180° in the clockwise direction and - arrow - lock it into place.
- Install the shaft seal for the separator in the transmission housing, refer to => [ Transmission Housing Separator Shaft Seals, Replacing ] 0B5A S-Tronic Transmission.
- Install the oil pump and the suction jet pump. Refer to => [ Oil Pump and Suction Jet Pump ] Service and Repair.
• The wiring set for the sensor module must be replaced when replacing the sensor module.
• Bolt tightening specification: position, - item 38 - => [ (Item 38) Bolt ] DSG Transmission Mechatronic (J743) Overview.
- Tighten the bolts - arrows - on the wiring set for the sensor module.
- Carefully press the connector on the sensor module completely opposite the direction of the arrow - arrow B -.
- Secure the fastener opposite the direction of the arrow - arrow A -.
- Make sure that the connector is secured and fastened correctly on the sensor module.
- Tighten the bolt - 1 -.
• Bolt tightening specification: position - item 38 - => [ (Item 38) Bolt ] DSG Transmission Mechatronic (J743) Overview.
- Mount the needle bearing - 2 - and spur gear - 1 - on the output shaft - 3 -.
- Insert the side shaft - 2 - with the bolt - 1 - into the transmission intermediate housing.
- Insert the side shaft - B - all the way onto the pinion and into the transmission cover.
Tighten the twelve-point bolt - A - for the side shaft - B - on the pinion as follows:
- Mount a twelve-point socket - C - (21 mm) with an extension - D - over the twelve-point bolt - A -.
- Insert the (T40217) with the outer splines - arrow 1 - into the inner splines - arrow 2 - on the side shaft.
- Tighten (T40217) to the transmission intermediate housing - arrows -.
- Tighten the bolt for the side shaft.
- Mount the oil guide for the input shaft - arrow -.
Installation is performed in reverse order of removal.
- Install the center differential housing and the center differential. Refer to => [ Center Differential Housing and Center Differential, Bolted Driveshaft ] Center Differential Housing and Center Differential, Bolted Driveshaft or => [ Center Differential Housing and Center Differential, Attached Driveshaft ] Center Differential Housing and Center Differential, Attached Driveshaft.
- Install DSG transmission Mechatronic (J743). Refer to => [ DSG Transmission Mechatronic (J743) ] DSG Transmission Mechatronic (J743).
- Install the dual clutch. Refer to => [ Dual Clutch ] Dual Clutch.
- Install the flywheel. Refer to => [ Flywheel ] Flywheel.