Mechatronic, With Transmission Removed

Mechatronic, with Transmission Removed

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 and/or oil pump.

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

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 (removed with 8 socket, tightening specification: 3 Nm). Its length determines the oil level in the transmission.

- Remove the overflow tube.

- Drain oil.

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

- Tighten the 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 the oil filter can help when making this decision.

- Insert the new filter with the seat facing downward and tighten the housing to 20 Nm.

- After performing repairs, the filter does not need to be changed again when filling with 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.

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

- Carefully release connector with a screwdriver.





CAUTION!
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 the DSG mechatronic.





CAUTION!
When handling the mechatronic, be particularly aware of the long sensor arm. Never lift the mechatronic by, or allow it to rest on, the sensor arm. If the sensor arm is damaged, mechatronic must be replaced.

- Store mechatronic properly.





Installing

CAUTION!
Never lift the mechatronic by, or allow it to rest on, the sensor arm. If the sensor arm is damaged, mechatronic must be replaced.

- Before installing, make sure that the transmission input speed sensor and clutch oil temperature sensor is installed.





- Replace both - O-rings - on the mechatronic connection if the old mechatronic is being reinstalled.





A new mechatronic has new rings

- Coat the O-rings with DSG transmission oil.

- Carefully place mechatronic on alignment pin - arrow -. Make sure the sensor arm is in the installation position.





CAUTION!
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 sensor and clutch oil temperature sensor 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 the oil without replacing filter.

- Perform basic measurement on the DSG mechatronic.