DSG Mechatronic, Transmission Removed, Removing and Installing

6 Spd. Direct Shift Automatic Transmission 02E

DSG Mechatronic, Transmission Removed, Removing and Installing
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.

Removing





- Remove plug - A - near pendulum support.
Up to transmission production date 09.20.2004, transmissions with two plugs were installed.
A plastic overflow tube is located behind this plug (with 8 mm hex socket head, tightening specifications 3 Nm). Its length determines the oil level in the 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.
- Insert the new filter with the seat facing downward and tighten the housing to 20 Nm.
- After 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.





- Carefully release connector with a screwdriver.
Be very careful. The connector locking mechanisms can break. If this happens, replace the sensor.

CAUTION! Do not pull on wire!

- Remove connector.





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





- Remove - bolts - diagonally. Begin with bolt - 1 -.
All 10 - bolts - must be replaced.





- Remove the Direct Shift Gearbox (DSG) mechatronic J743.
When handling the 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 the arm is damaged, the 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 arm is damaged, the mechatronic must be replaced!





- Before installing, make sure that the transmission input speed (RPM) sensor G182 and clutch oil temperature sensor G509 is installed.





- Replace both - O-rings - on the mechatronic connection, if an old mechatronic is being installed again.
(A new mechatronic naturally already has new rings).
- Coat the O-rings with DSG transmission oil.





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

CAUTION! Do not pinch line!





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





- Install transmission input speed (RPM) sensor G182 and clutch oil temperature sensor G509 line first in clamp - II -. Then in clamp - I -.
- Press connector onto mechatronic.
Small oil pump cover and large cover bolts must always be replaced.





The seal on the 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.