DSG Mechatronic, Transmission Installed, Removing and Installing

6 Spd. Direct Shift Automatic Transmission 02E

DSG Mechatronic, Transmission Installed, Removing and Installing

Special tools, testers and auxiliary items required





^ Torque wrench V.A.G. 1331





^ Used oil collection and extraction device V.A.G. 1782

Removing
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 the oil filter.
- Place selector lever in position P.
- Disconnect battery Ground (GND) strap with ignition system switched off.
- Remove noise insulation.
If present:
- Remove connecting hose between charge air cooler and charge air tube.
- Remove cable bracket from large front transmission cover (2 nuts M6)
- Release mechatronic connector retainer by rotating and remove connector.
- Position lines in cover area upward and tie up.
- Place the used oil collection and extraction device V.A.G. 1782 under transmission.





- 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 behind this plug (with 8 mm hex socket head, tightening specification: 3 Nm). Its length determines the oil level in the transmission.
- Remove this oil tube.
Approximately 5.0 liters of oil will flow out. Used oil collection and extraction device V.A.G. 1782 should remain below transmission from now on.
In regard to contaminated oil, also observe information on changing oil filter.
- Reinstall overflow tube, 3 Nm.





- Loosen cover bolts - arrows - diagonally and remove.
- Guide cover on starter bolt.
- Remove cover and seal.
- Small oil pump cover and large cover bolts must always be replaced.
Large cover seal must also be replaced.





- Remove oil pump cover - A -.
Before handling mechatronic, touch a grounded object again.





- Carefully release the connector of the transmission input speed (RPM) sensor G182 with clutch oil temperature sensor G509 using a small screwdriver - 1 - and at the same time carefully pry out the connector using a second screwdriver - 2 -.
Be very careful. The connector locking mechanisms can break. If this happens, replace the sensor.

CAUTION! Do not pull on wire!

- Remove connector.
- Remove wire from retaining tabs - arrows -.





- Loosen bolts - 1 - through - 10 - in the specified order and remove.
In order to have enough free space to remove the mechatronic, the pendulum support can be removed.
Then the transmission can be pressed down and back slightly.





- Pull mechatronic out of transmission housing far enough until sensor arm - B - on rear side is no longer located in transmission housing.
When handling the mechatronic, be particularly aware of the long sensor arm.
2Carefully swivel Direct Shift Gearbox (DSG) mechatronic J743 downward.





Store mechatronic properly

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

Installing

CAUTION! Before handling mechatronic, touch a grounded object again.






- Carefully insert the Direct Shift Gearbox (DSG) mechatronic J743 into the transmission housing.

Make sure alignment pin - A - in transmission housing - arrow 1 - and sensor arm - B - in guide - arrow 2 - are seated correctly on transmission housing.

CAUTION! Do not pinch line!





- Install new bolts - 1 - to - 10 - hand-tight.
- Tighten bolts in specified sequence to 5 Nm ± 90 degree (1/4 additional rotation).
- Engage wire - A - first into top, then into bottom retaining tab - arrows -.
- Connect and engage connector.





- Replace both - O-rings -, if the old mechatronic is being installed again.
- Coat the O-rings with DSG transmission oil.
- Clean the cover gasket and sealing surfaces on the transmission.
- Ensure correct seal seating.
- Place cover over mechatronic without pinching any lines.





- Install new bolts - arrows - and tighten diagonally in multiple stages to 10 Nm.





- Set new oil pump cover - A - in place and tighten bolts - arrows - in diagonal sequence and in multiple stages to 8 Nm.
- Install cable bracket on large cover and tighten nuts to 10 Nm.
- Connect the connector of the Direct Shift Gearbox (DSG) mechatronic J743 and engage retainer by turning.
- If present: Install connecting hose between charge air cooler and charge air tube.
- Reinstall any vehicle parts removed.
- Connect battery Ground (GND) strap.
- Do not start engine!
- Replace the DSG oil and filter.
- Install noise insulation. Refer to:
- Perform basic measurement on Direct Shift Gearbox (DSG) mechatronic J743.