DSG Transmission Mechatronic (J743)

DSG Transmission Mechatronic (J743)

Special tools, testers and auxiliary items required

• Oil Collection and Extraction Device (V.A.G 1782)

• Vehicle Diagnostic Tester

Removing

• General repair instructions, refer to => [ Repair Information ] Repair Information.

• Rules for cleanliness when working on the S-Tronic transmission. Refer to => [ Clean Working Conditions ] Clean Working Conditions.

There is a risk of destroying the transmission control module (Mechatronic) with static discharge.

• Always "discharge" the static electricity. Do this by touching a grounded object, for example vehicle ground, the vehicle or the hoist.

• Do not touch contacts in transmission connector with hands.

Transmission Installed






- Remove the noise insulation - 1 and 2 -.

There is a risk of damaging the transmission.

• Do not start the engine if there is no ATF in the transmission and the Direct Shift Gearbox (DSG(R)) transmission Mechatronic (J743) is removed.

- Move the selector lever into "P".






- Turn off the ignition and remove the key.

- Disconnect the connector on transmission by rotating screw connections counter-clockwise - arrow -.

Transmission, Removed or Installed






- Remove the ATF oil pan. Refer to => [ Automatic Transmission Fluid Oil Pan ] Service and Repair.

- Remove the bolt - 1 -.

- Turn the connector housing - 2 - counter-clockwise - arrow - and remove it.

Vehicles with an ATF Pipe Filter






- Remove the bolts - arrows - and then slightly pull out the connection for the ATF pipes.

• The connection with the ATF pipe removed is shown in the illustration.

Vehicles with an ATF Filter






- Remove the bolts - arrows - and pull the ATF filter housing out slightly.

All Vehicles






- Carefully pull the ATF filter to the rear and off the Mechatronic - arrow -.








There is a risk of destroying the transmission control module (Mechatronic) with static discharge.

• Always "discharge" the static electricity. Do this by touching a grounded object, for example vehicle ground, the vehicle or the hoist.

• Do not touch contacts in transmission connector with hands.

- Pull the retainer - arrow 1 -, push the release down - arrow 2 - and disconnect the connector.

- Remove the bolts in reverse order: - 6 to 1 -.






Risk of causing damage to the Mechatronic.

• Only bolts - 6 through 1 - may be loosened.

• If other bolts are loosened, this may affect the function of the Mechatronic unit or it may come apart.

• The sealing surface must not be damaged.

• The Mechatronic fits partially inside the transmission.

• If the Mechatronic must be removed, then a second technician will be needed to keep it from falling. Another alternative, the bolts - 1 and 2 - can be installed slightly to hold the Mechatronic in place while it is being removed.

- Remove the Mechatronic.

Danger of damaging the sensor on the back side of the Mechatronic.

• Lay the Mechatronic with the bolt head side facing down only.

Installing






• Tightening specifications, refer to => [ DSG Transmission Mechatronic (J743) Overview ] DSG Transmission Mechatronic (J743) Overview.

• Replace the Mechatronic O-rings and bolts.

• Do not bend the ATF oil pipe brackets.

- If equipped: Remove the bolt - arrow -.

- Remove ATF pressure pipes (clutch pressure) - 1 and 2 -.

• The ATF pressure pipes (clutch pressure) - 1 and 2 - in transmissions for the new version are a single unit and made out of plastic. In this case, the ATF pressure pipe (clutch pressure) must be replaced. There is no bolt - arrow - and no bracket for the ATF pressure pipe.

- For metal ATF pressure pipes (coupling pressure): Replace the O-rings on the ATF pressure pipes - 1 and 2 -.

- For plastic ATF pressure pipes (coupling pressure): Replace the ATF pressure pipes - 1 and 2 -.

- Remove the ATF pipes - 3 through 5 -.

• The ATF pipes - 3 through 5 - in transmissions for the new version are a single unit and made out of plastic. In this case, the ATF pipes must be replaced.

- Metal ATF pipe: replace the O-rings on the ATF pipes - 3 through 5 -.

- Plastic ATF pipes: replace ATF pipes - 3 through 5 -.

- Coat all of the O-rings with ATF.

- Insert all of the ATF pipes - 1 through 5 - again.

- If equipped: Tighten the bracket and the bolt - arrow -.

• Make sure all shift forks and gear positions are in the center position before installing the DSG transmission Mechatronic.

Adjust Shift Forks






- First check the shift positions for the shift forks - 1 through 4 - by hand.

Each shift fork has three positions:

• - G - is engaged

• Idle - N - (center position)

• - G - is engaged

- Move all four shift forks one time into each position - arrows - one after the other.

- After doing this, move the shift forks back into the center position - N -.

Adjust Gear Selector






There is a risk of destroying the transmission control module (Mechatronic) with static discharge.

• Always "discharge" the static electricity. Do this by touching a grounded object, for example vehicle ground, the vehicle or the hoist.

• Do not touch contacts in the transmission connector with hands.

• Do not pry out the plunger on the sensors.

The gear shifter must be adjusted differently depending on the date of manufacture of the Mechatronic.

The date of manufacture is located only on the Mechatronic identification - arrow -.

The Mechatronic identification consists of:






The gear positions must be adjusted to a different adjustment value from Mechatronic "L31B1138".

• A Mechatronic with the identification. "L31A1140" was built before Mechatronic "L31B1138" because it was built by the 1st shift (A1) on a Monday.

• A Mechatronic with the identification "L31C1009" was built after Mechatronic "L31B1138" because it was built by the 3rd shift (C1) on Monday.

- Move the gear position back and forth and set the 4 gear positions on the back of the Mechatronic in the center position to dimension - a -.






For Mechatronic with identification through "L31B1137":

• - a - = 28 mm

For Mechatronic with identification from "L31B1137":

• - a - = 32 mm

- Align the gear selector yokes - arrows - so that they engage into the eyes in the shift fork when being installed.






- Insert the Mechatronic into the transmission housing.






• The Mechatronic and its bolts must fit easily into the holes in the transmission.

• If the Mechatronic does not go in easily, then it is possible that a shift fork or a gear selector is not in its center position. Check the center position and adjust if necessary.

After installing the Mechatronic:






- Using a flashlight, check all the gear selectors through the opening between the Mechatronic and the transmission housing.

• All four gear selector yokes must fit correctly in the shift fork eyes.

- Tighten the Mechatronic bolts. Refer to => [ Mechatronic, Tightening Specification and Sequence ] DSG Transmission Mechatronic (J743) Overview.

Install in reverse order, paying attention to the following:

There is a risk of destroying the transmission control module (Mechatronic) with static discharge.

• Always "discharge" the static electricity. Do this by touching a grounded object, for example vehicle ground, the vehicle or the hoist.

• Do not touch contacts in the transmission connector with hands.

- Make sure the connector is correctly connected to the Mechatronic.

- Install the ATF filter. Refer to => [ ATF Suction Filter ] ATF Suction Filter.

- Install the ATF pan. Refer to => [ Automatic Transmission Fluid Oil Pan ] Service and Repair.

Transmission Removed

- Install the transmission.

Transmission Installed

- Fill the ATF.

• After replacing the DSG transmission Mechatronic , the corresponding "Guided Functions" must be performed using the vehicle diagnostic tester.