DSG(R) Transmission Mechatronic J743, Transmission Installed
DSG(R) 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" Mechatronic unit and/or oil pump.
In regard to "contaminated oil", also observe the information on changing the oil filter. Refer to => [ When To Change the Transmission Oil Filter ] Description and Operation.
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.
with a Diesel Engine
- Remove the charge air hose between the charge air cooler and charge air pipe.
with a Gas Engine
• When the engine is warm, the cooling system is under pressure.
• Cover the cap on the expansion tank with a cloth and open it carefully before removing the coolant hoses.
- Remove the lower coolant hose from the radiator and tie it up, in order to drain the coolant.
Continuation for All
• It is possible that components, 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 components could be:
• The fan shroud - arrow -
• Additional lines for the Air Conditioning (A/C) system
• Charge or cold air pipes
Risk of destroying the Mechatronic unit with static electricity.
• Do not touch the contacts in the Mechatronic unit connector with hands.
- To discharge any static electricity, touch a ground with hand (without wearing a glove). Refer to => [ Electrical Component Location Overview ] 02E Transmission (Direct Shift Gearbox).
- Release and remove the connector - 1 - for the Mechatronic unit by turning it in the direction of the starter.
• The connector is located on the transmission near the starter - A -.
- Remove the electrical wires from the bracket, then remove the bracket nuts - arrows - (two M6 nuts) and the bracket from the transmission front cover.
- Route the wires near the transmission front cover upward and secure them.
- Place the used oil collecting and extracting device (V.A.G 1782) under the transmission near the cover.
Oil will leak out of the cover when the bolts are loosened. Risk of injury due to hot oil.
- Loosen the transmission front cover bolts - arrows - diagonally and then remove them. Hold the cover in place while doing this.
- Allow the oil to drain from the cover.
- Then, remove the cover and gasket.
• Always replace the front transmission cover gasket and bolts as well as the oil pump cover and bolts.
- Remove the left front wheel housing liner..
- Remove the oil pump cover bolts - arrows - and the cover - A -.
- Remove the pendulum support bolts - 2 and 3 - from the transmission.
The transmission can now be pushed down slightly to remove the Mechatronic unit.
Before handling the Mechatronic unit, touch a grounded object. Refer to => [ Electrical Component Location Overview ] 02E Transmission (Direct Shift Gearbox).
- Disconnect the transmission input speed sensor and clutch oil temperature sensor connector - 1 - 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 first screwdriver - 1 -. Do not use this screwdriver as a lever.
• Loosen the connector using the second screwdriver - 2 -.
• Be very careful. The connector locking mechanism can break. Replace the sensor if this happens.
Do not pull on the wire.
- Remove the connector.
- First, remove the wire from under the lower clip - arrow I -.
- Then, remove the wire from under the upper clip - arrow II - and lay it aside. Do not kink the wire.
- Loosen and remove the Mechatronic unit bolts in sequence - 1 through 10 -.
- Carefully pull the Mechatronic unit out of transmission housing far enough until the sensor arm - B - on 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. Refer to => [ Electrical Component Location Overview ] 02E Transmission (Direct Shift Gearbox).
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.
- Make sure the Mechatronic unit is installed correctly.
- Tighten the new Mechatronic unit bolts - 1 through 10 - hand tight.
- Tighten the new bolts in sequence - 1 through 10 - to 5 Nm + an additional 90° (1/4) turn.
- Hook the wire - A - first under the upper clip, then under the lower clip - arrows -.
- Connect the transmission input speed sensor and clutch oil temperature sensor connector.
- Replace both O-rings if reinstalling the old Mechatronic unit.
- Coat the O-rings with the Direct Shift Gearbox (DSG(R)) oil.
A new Mechatronic unit already has new O-rings.
- Clean the transmission front cover gasket and transmission sealing surfaces.
- Make sure the gasket fits correctly.
- Place the front cover - A - over the Mechatronic unit. Be careful not to pinch any wires when doing this.
- Install the new bolts - arrows - and tighten them to 16 Nm diagonally and in several steps.
- Install the bracket and nuts - arrows - to the cover.
Tightening specification for the nuts: 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.
- Install the left front wheel housing liner..
Connect the connector - A - to the Mechatronic unit as follows:
- The arrow - D - on the Mechatronic unit - B - must line up with the arrow on the connector - A - as well as with the tab - C -.
- Carefully insert the connector - A - all the way in and lock it in by turning it in the - direction of the arrow -.
- Install the pendulum support bolts to the transmission.
with a Diesel Engine
- Install the charge air hose between the charge air cooler and charge air pipe.
with a Gas Engine
- Install the lower coolant hose to the radiator and fill the coolant.
Do not start engine during the coolant level checking if the oil has not been added yet.
Continuation for All
- Reinstall any vehicle components that may have been removed.
- Connect the battery ground cable.
- Do not start the engine.
- Change the oil filter if the oil is dirty.
- Replace the DSG(R) oil and filter. Refer to => [ DSG(R) Oil, Draining and Filling ] DSG(R) Oil, Draining and Filling
- Move the used oil collecting and extracting device (V.A.G 1782) under the transmission near the oil drain and check plug.
- Remove the oil drain and check plug - arrow -.
- Install the quick release coupling from the adapter for oil filling (VAS 6262 A) into the plug hole hand tight.
- Shake the container before opening.
- Connect the oil container to the adapter for oil filling (VAS 6262 A) e. Be sure to read the instructions. Refer to => [ Note the following information: ] DSG(R) Oil Level, Checking.
- Connect the adapter for oil filling (VAS 6262 A) to the quick release coupling.
- Fill with 3 liters of DSG(R) oil.
- To change containers, close the shut off valve or hold the adapter for oil filling (VAS 6262 A) higher than the transmission.
Start the engine and check the oil level. Refer to => [ DSG(R) Oil Level, Checking ] DSG(R) Oil Level, Checking. The adapter for oil filling (VAS 6262 A) remains installed.
- Install the noise insulation.
- Connect the vehicle diagnostic tester.
- Perform a basic measurement on the Mechatronic unit.