DSG Transmission Mechatronic (J743), Transmission Removed

DSG Transmission Mechatronic (J743), Transmission Removed

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)

• Release Tool (T10465)

Always make sure that no dirt enters an open transmission. Dirt entering an open transmission, can cause a malfunction especially with an open Mechatronic unit and/or oil pump.

In regard to contaminated oil, observe information on changing the oil filter. Refer to => [ When To Change Transmission Oil Filter ] When To Change Transmission Oil Filter.

Removing

- Place the used oil collecting and extracting device (V.A.G 1782) or a drip tray under the transmission.

- Remove the transmission oil drain and inspection plug - arrow - and drain the transmission oil.






A plastic overflow tube is located in this hole (with a 8 mm hex socket head, tightening specification: 3 Nm).

- Remove this overflow tube and drain the rest of the transmission oil.

• Approximately 5.0 liters of transmission oil will drain. Leave the used oil collecting and extracting device (V.A.G 1782) or the drip tray under the transmission.

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.

- Tighten the overflow tube to 3 Nm.

- If it is necessary, remove the filter.






There are often uncertainties as to whether the filter must be replaced or not.

For information on changing the oil filter, refer to => [ When To Change Transmission Oil Filter ] When To Change Transmission Oil Filter.

- Insert the new filter with the seat facing downward and tighten the filter housing to 20 Nm.

• After repairing, you do not have to change filter again when filling oil.

- Remove the transmission cover bolts and cover and the oil pump cover bolts and cover.






• Always replace the oil pump cover, the oil pump cover bolts as well as the gasket and the transmission cover bolts.

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 the connector.

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






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

- Diagonally loosen the bolts - 1 through 10 -. Start with bolt - 1 -.






Replace all 10 bolts.

- Remove the Mechatronic unit






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

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

Replace the Mechatronic if the sensor arm gets damaged.

Store the Mechatronic unit properly.






Installing

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.

- Make sure the transmission input speed sensor and clutch oil temperature sensor is installed.






- Replace both O-rings for the Mechatronic unit connection if an old Mechatronic unit is being reinstalled.






A new Mechatronic unit already has new O-rings.

- Coat the O-rings with Direct Shift Gearbox (DSG) transmission oil.

- Carefully install the Mechatronic unit on the alignment pin - arrow -. The goal is for the sensor arm to be in its installed position.






- The sensor arm must not touch the sensor wheel.

- Do not pinch the wire.

Really pay attention to this: Do not pinch the wire!

All of the bolts - 1 through 10 - must be replaced.






- Install the bolts - 1 through 10 - by hand.

- Tighten all the bolts - 1 through 10 - in a diagonal sequence to 5 Nm. Then tighten the bolts an addition 90° (1/4) turn in the same order. Start with bolt - 1 -.

- Install the wire, first under the upper tab - arrow II -, then under the lower tab - arrow I -.






- Press the connector onto the Mechatronic unit.

Always replace the oil pump cover and the bolts for the transmission cover.

Replace the transmission cover gasket.






- Tighten the transmission cover bolts diagonally to 10 Nm.

After installing the transmission,

- Fill the oil without replacing the filter. Refer to => [ Transmission Oil, Draining and Filling ] Transmission Oil, Draining and Filling.

- Perform a basic measurement on the Mechatronic unit.