DSG Transmission Mechatronic (J743), Transmission Installed

DSG Transmission Mechatronic (J743), Transmission Installed

Special tools, testers and auxiliary items required

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Used Oil Collecting and Extracting Device (V.A.G 1782)

• Adapter for Oil Filling (VAS 6262 A)

• Release Tool (T10465)

Removing

Always make sure that no dirt enters an open transmission.

Dirt entering an open transmission can cause a malfunction especially with an open Direct Shift Gearbox (DSG) transmission Mechatronic and/or oil pump.

In regard to contaminated fluid, also observe the information on changing the filter. Refer to => [ When To Change the Fluid Filter : ] DSG Transmission Fluid.

The Mechatronic unit can get stuck on the alignment pins when the transmission is very warm. Let the transmission cold down.

- Move the selector lever into the "P" position.

- Turn off the ignition and disconnect the battery ground cable.

- Remove the noise insulation.

If present:

- Remove the charge air hose between the charge air cooler and the charge air pipe.






• It is possible that parts, which have nothing to do with the Mechatronic unit, will have to be removed. It depends on the vehicle equipment. Make sure there is enough room around the Mechatronic unit.

• Depending on the vehicle, the parts could be:






• Radiator fan shroud - arrow -

• Additional lines for the Air Conditioning (A/C) system

• Charge air pipes

- Disconnect the connector - 1 -.






• The connector is located on the transmission near the starter - A -.

- Remove the wire and bracket from the large front transmission cover - arrows - (2 M6 nuts).






Tightening specification for the nuts: 10 Nm

- Position the lines in the area of the cover upward and secure them.

- Place the used oil collecting and extracting device (V.A.G 1782) under the transmission near the large cover.


Transmission fluid will leak out of the cover when the bolts are removed. Risk of injury due to hot transmission fluid.

- Loosen the cover bolts - arrows - diagonally and remove them. Hold the cover in place while doing this.






- Drain the transmission fluid and remove the cover and gasket.

About 3 liters of fluid will drain out.

• Always replace the small oil pump cover, the gasket and the bolts for the large cover.

- Remove the oil pump cover bolts - arrows - and cover - A -.






- Remove the pendulum support bolts - 2 and 3 - from the transmission.






The transmission can now be pressed down slightly to remove the Mechatronic unit.

Before handling the Mechatronic unit, touch a grounded object. Refer to => [ Electrical Components ] Electrical Components.

- Disconnect the connector - 1 - from the transmission input speed sensor (G182) and clutch oil temperature sensor (G509) using the release tool (T10465).






• If the release tool (T10465) is not available, the connector can be disconnected carefully using two screwdrivers as follows:






• Press only on the release with the screwdriver - 1 -. Do not use the screwdriver as a lever.

• Loosen the connector with the screwdriver - 2 -.

• Be very careful. The connector locking mechanisms can break. Replace the sensor if this happens.

Do not pull on the wire.

- Remove the connector.

- First, remove the wire from the lower tab - arrow I -.






- Then, remove the wire from the upper tab - arrow II - and lay aside. Do not kink the wire.

- Loosen and remove the bolts - 1 through 10 - in sequence.






- Carefully pull the Mechatronic unit out of transmission housing far enough until the sensor arm - B - on the rear side is no longer located in the transmission housing.






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

- Carefully move the Mechatronic unit downward.

Store the Mechatronic unit properly.







Never lift the Mechatronic unit by the sensor arm and never let it rest on the arm.

Replace the Mechatronic unit if the arm gets damaged.

Installing

Before handling the Mechatronic unit, touch a grounded object again. Refer to => [ Electrical Components ] Electrical Components.

Replace the Mechatronic unit if the arm gets damaged.

• The Mechatronic unit and the transmission must be the same temperature. Otherwise the alignment pins will not clamp during installation.

• Do not pinch the wire.

- Carefully mount the Mechatronic unit onto the alignment pins - arrow -. The goal is for the sensor arm to be in its installed position.






- Hold the Mechatronic unit facing up. The sensor arm must not touch the sensor wheel. (see the insert).

- Make sure the Mechatronic unit is installed correctly.

- Install the new bolts - 1 through 10 - hand tight.






- Tighten the bolts to 5 Nm + 90° (1/4) additional turn in the specified sequence.

- Hook the wire - A - first under the upper, and then under the lower tabs - arrows -.

- Connect the connector.

- Replace both O-rings if reinstalling the old Mechatronic unit.






- Lubricate the O-rings with DSG transmission fluid.

A new Mechatronic unit already has new O-rings.

- Clean the cover and transmission sealing surfaces.

- Make sure the gasket fits correctly.

- Place the cover - A - over the Mechatronic unit. Be careful not to pinch any wires when doing this.






- Install new bolts - arrows - and tighten them to 10 Nm diagonally and in several steps.

- Install the wire bracket to the cover and then tighten the nuts to 10 Nm.

- Set the new oil pump cover - A - in place and tighten the bolts - arrows - in a diagonal sequence and in stages to 8 Nm.






- Connect the connector - 1 - to the Mechatronic unit and turn the locking mechanism.






- Install the hose between the charge air cooler and the charge air pipe, if was removed earlier.

- Install the pendulum support to the transmission using new bolts.

- Reinstall any vehicle parts removed.

- Connect the battery ground cable.

- Do not start the engine.

- Change the filter if the fluid is dirty.

- Replace the DSG fluid and filter. Refer to => [ Transmission Fluid Level, Checking and Filling ] Transmission Fluid Level, Checking and Filling.

- Place the used oil collecting and extracting device (V.A.G 1782) under the transmission near the drain plug.

- Remove the drain plug - arrow - near the pendulum support.






- Install the adapter for oil filling (VAS 6262 A) into the plug hole hand tight.






- Shake the bottles before opening.






- Attach the adapter for oil filling (VAS 6262 A) to the oil bottle. Be sure to read the instructions. Refer to => [ Note the following information: ] Transmission Fluid Level, Checking and Filling.

- Fill with 3 liters of transmission fluid.

- To change containers, close the shut off lever or hold the adapter for oil filling (VAS 6262 A) higher than the transmission.

Start the engine and check the fluid level. The adapter for oil filling (VAS 6262 A) remains installed.

- Check the fluid level and fill if necessary. Refer to => [ Transmission Fluid Level, Checking and Filling ] Transmission Fluid Level, Checking and Filling.

- Install the noise insulation.

- Connect the vehicle diagnostic tester.

- Perform the basic measurement on the Mechatronic unit.