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 Direct Shift Gearbox (DSG) transmission Mechatronic and/or oil pump.

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

Removing

- Remove the drain plug - A - near the 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 (with a 8 mm hex socket head, tightening specification: 3 Nm). Its length determines the fluid level in the transmission.

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

- Remove the overflow tube.

- Drain the fluid.

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

- 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 filter, refer to => [ When To Change the Fluid Filter : ] DSG Transmission Fluid.

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

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

- Remove both covers.






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

Replace the gasket for the large cover.

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

- Diagonally, loosen the bolts - 1 through 10. - Start with the 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 unit if the 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 arm gets damaged.

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






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






A new Mechatronic unit already has new rings.

- Lubricate the O-rings with DSG transmission fluid.

- Carefully place 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. (see the insert).

- 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 them an addition 90° (1/4) turn in the same order. Start with the bolt - 1 -.

- Install the transmission input speed sensor and clutch oil temperature sensor wire under the upper tab - arrow II - first. Then install the wire under the lower tab - arrow I -.






- Press the connector onto the Mechatronic unit.

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

Replace the gasket fro the large cover.






- Diagonally tighten the cover bolts to 10 Nm.

After installing the transmission

- Fill with fluid, but without replacing the filter. Refer to => [ Transmission Fluid Level, Checking and Filling ] Transmission Fluid Level, Checking and Filling.

- Perform a basic measurement on the Mechatronic unit.