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 on open transmission, can cause a malfunction especially with an open Mechatronic unit and/or oil pump.
In regard to contaminated oil, observe the information on changing the oil filter. Refer to => [ When To Change Transmission Oil Filter ] When To Change Transmission Oil Filter.
The Mechatronic unit can get stuck on the alignment pins when the transmission is very warm. Allow the transmission to 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:
• Fan shroud - arrow -
• Additional lines for the Air Conditioning (A/C) system
• Charge air pipes
Risk of destroying the Mechatronic unit with static electricity.
• Do not touch contacts in the Mechatronic unit connector with hands.
- To discharge any static electricity, touch a grounded object without wearing a glove. Refer to => [ Electrical Components ] Electrical Components.
- Turn the Mechatronic unit connector - 1 - counterclockwise and then disconnect it.
• The connector is located on the transmission near the starter - A -.
- Remove the electric wires, the bracket nuts - arrows - (two M6 nuts) and bracket from the front transmission cover.
Tightening specification for the nuts: 10 Nm
- Route the wires near the transmission cover upward and secure them.
- Place the used oil collecting and extracting device (V.A.G 1782) under the transmission near the transmission cover.
Gear oil will leak out of the cover when the bolts are removed. Risk of injury due to hot gear oil.
- Loosen the transmission cover bolts - arrows - diagonally first and then remove them. Hold the cover in place while doing this.
- Drain the gear oil and remove the cover and seal.
Approximately 3 liters of transmission oil will drain out.
• Always replace the oil pump cover, the oil pump cover bolts as well as the gasket and the transmission cover bolts.
- Remove the oil pump cover bolts - arrows - and the oil pump cover - A -.
- Remove the pendulum support bolts - 2 and 3 - that attach the pendulum support to 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 removed by 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.
- Disconnect connector.
- First, remove the wire from the lower tab - arrow I -.
- Than, remove the wire from the upper clip - arrow II - and lay aside. Do not kink the wire.
- Loosen and remove the Mechatronic unit bolts - 1 through 10 - in the specified 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 sensor 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 sensor arm gets damaged.
• The Mechatronic unit and the transmission must be the same temperature. Otherwise the alignment pins will not clamp in during installation.
• Do not pinch the wire.
- Carefully install 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.
- Make sure the Mechatronic unit is installed correctly.
- Tighten the new Mechatronic unit bolts - 1 through 10 - hand tight.
- Tighten the bolts - 1 through 10 - to 5 Nm + 90° (1/4) in the specified sequence.
- Hook the wire - A - first under the upper tab, and then under the lower tab - arrows -.
- Connect the connector.
- Replace both O-rings if installing the old Mechatronic unit.
- Coat the O-rings with Direct Shift Gearbox (DSG) transmission oil.
A new Mechatronic unit already has new O-rings.
- Replace the transmission cover gasket.
- Clean the sealing surface on the transmission.
- Make sure the gasket fits correctly.
- Place the transmission cover - A - over the Mechatronic unit. Be careful not to pinch any wires when doing this.
- Install new bolts - arrows - and tighten to 10 Nm, diagonally and in several steps.
- Attach the cable bracket to the transmission cover and tighten the nuts - arrows - to 10 Nm.
- Set the new oil pump cover - A - in place and tighten the new bolts - arrows - in a diagonal sequence and in several steps to 8 Nm.
Connect the connector - A - to the Mechatronic unit as follows:
- The arrows - D - on the Mechatronic unit - B -, the connector - A - as well as the tab - C - must line up.
- Connect the connector - A - carefully all the way and then turn the lock clockwise in the - direction of the arrow -.
- Install the charge air 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 oil is dirty.
- Replace the DSG oil and filter. Refer to => [ Transmission Oil, Draining and Filling ] Transmission Oil, Draining and Filling.
- Move the used oil collecting and extracting device (V.A.G 1782) under the transmission near the transmission oil drain and inspection plug.
- Remove the transmission oil drain and inspection plug - arrow -.
- Install the fitting from the adapter for oil filling (VAS 6262 A) into the plug hole hand tight.
- Shake the bottles before opening.
- Connect 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 Oil Level, Checking and Filling.
- Fill with 3 liters of transmission oil.
- 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, as necessary. Refer to => [ Transmission Oil Level, Checking and Filling ] Transmission Oil Level, Checking and Filling.
- Install the noise insulation.
- Connect the vehicle diagnostic tester.
- Perform basic measurement on the Mechatronic unit.