Mechatronic, With Transmission Removed

Mechatronic, with Transmission Removed - 02E, 6 Speed DSG A/T FWD
Always make sure that no dirt enters an open transmission. Dirt entering can cause a transmission malfunction especially with open DSG mechatronic J743 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 (8 mm hex socket head, tightening specification: 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.

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.





- 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-.
- Than remove from second clamp -arrow II- and lay aside. Do not kink line.





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

All 10 - bolts - must be replaced.





- Remove the 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 arm is damaged, Mechatronic must be replaced.
- Store Mechatronic properly.





Storing Mechatronic Properly

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 G182 and clutch oil temperature sensor G509 is installed.





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

(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 is in the installation position.
- 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 - II -. Then in clamp - 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 J743.