Direct Shift Gearbox (DSG) Mechatronic J743 (Transmission Removed), Removing and Installing

Direct Shift Gearbox (DSG) Mechatronic J743 (transmission removed), removing and installing 02E, 6 Speed Direct Shift A/T
Always make sure that no dirt enters an open transmission. Dirt entering can cause a transmission malfunction especially with open Direct Shift Gearbox (DSG) Mechatronic J743 and/or oil pump.

In regard to contaminated oil, also observe information on changing oil filter.

Mechatronic, removing





- Remove plug - A - near pendulum support.

Up to transmission production date "September 20, 2004", transmissions with two plugs were installed.

A plastic overflow tube is located in this hole (with 8 mm hex socket head, torque specification: 3 Nm). Its length determines oil level in transmission.

- Remove this oil tube.
- Drain oil.

In regard to contaminated oil, also observe information on changing the oil filter.

- Hand-tighten overflow tube to 3 Nm.





- If it is necessary, remove filter.

There are often uncertainties as to whether the filter must be replaced or not.

The information on changing oil filter can help when making this decision.





- Insert new filter with seat facing downward and tighten housing to 20 Nm.
- After repairing, you do not have to change filter again when filling oil.





- Remove both - covers -

Small oil pump cover and large cover bolts must always be replaced.

Large cover seal must also be replaced.





Before handling Mechatronic, touch a grounded object again.





- Carefully release connector with a screwdriver.

Be very careful. The connector locking mechanisms can break. If this happens, replace the sensor.

Do not pull on wire!

- Remove connector.





- First remove line from lower clamp - arrow I -.
- Then remove from second clamp - arrow II - and lay aside. Do not kink line.





- Remove - bolts - diagonally. Begin with bolt - 1 -.

All 10 - bolts - must be replaced

- Remove Direct Shift Gearbox (DSG) Mechatronic J743.





When handling Mechatronic, be particularly aware of the long sensor arm.

CAUTION! Never lift the Mechatronic by, or allow it to rest on, the sensor arm.





If arm is damaged, Mechatronic must be replaced.

- Store Mechatronic properly.





Store Mechatronic properly

Mechatronic, installing

CAUTION! Never lift the Mechatronic by, or allow it to rest on, the sensor arm.





If arm is damaged, Mechatronic must be replaced.





- Before installing, make sure that the Transmission Input Speed (RPM) Sensor G 182 and Clutch Oil Temperature Sensor G509 is installed.





- Replace both - sealing rings - at Mechatronic connection if an old Mechatronic is reinstalled.

(A new Mechatronic naturally already has new rings)

- Coat O-rings with Direct Shift transmission oil.





- Carefully place Mechatronic on alignment pin - arrow -. Ensure sensor arm finds - location -.
- Do not pinch line.

Really pay attention to this: Do not pinch line!





All 10 - bolts - must be replaced.

- First install all - bolts - by hand.
- Then diagonally tighten all 10 - bolts - to 5 Nm, finally rotate an additional 90° in same sequence. Begin with bolt - 1 -.





- Install Transmission Input Speed (RPM) Sensor G182 and Clutch Oil Temperature Sensor G509 line first in clamp - arrow II -. Then in clamp - arrow I -.
- Press connector onto Mechatronic.

Small oil pump cover and large cover bolts must always be replaced.





- Seal - on large - cover - must also be replaced.
- Tighten cover bolts diagonally to 10 Nm.

After installing transmission

- Fill oil without replacing filter.
- Perform basic measurement on Direct Shift Gearbox (DSG) Mechatronic J743.