DSG(R) Transmission Mechatronic J743, Transmission Removed

DSG(R) 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", also observe the information on changing the oil filter. Refer to => [ When To Change the Transmission Oil Filter ] Description and Operation.

Removing

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

- Remove the oil drain and check plug - arrow -.






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

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

• Approximately 5.0 liters of 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", also observe information on changing the oil filter. Refer to => [ When To Change the Transmission Oil Filter ] Description and Operation.

- Tighten the overflow tube to 3 Nm.

- If it is necessary, remove the oil filter.






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

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

- Loosen transmission front cover bolts - arrows - diagonally and then remove them. Remove the cover - A -.






• Always replace the transmission front cover bolts.

- Remove the oil pump cover bolts - arrows - and remove the cover - A -.






• Always replace the oil pump cover bolts and the cover.

Touch a grounded object before touching the Mechatronic unit. 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 with 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 the Mechatronic unit bolts diagonally and in sequence - 1 through 10 -. Remove the bolts.






Replace all 10 bolts.

- Remove the Mechatronic unit.






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

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

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






- Replace both O-rings on the connection if the old Mechatronic unit is going to be reinstalled.






A new Mechatronic unit already has new O-rings.

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

- 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.

- Do not pinch the wire.

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






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

- Tighten all the bolts to 5 Nm + an additional 90 (1/4) turn, starting with bolt - 1 -, in sequence.

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






- Press the connector onto the Mechatronic unit.

- Clean the transmission front cover gasket and transmission sealing surfaces.

- Make sure the gasket fits correctly.

- Place the transmission front cover - A - over the Mechatronic unit. Be careful not to pinch any wires when doing this.






- Install the new front cover bolts - arrows - and tighten them to 16 Nm diagonally and in several steps.

- 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 transmission. Refer to => [ Transmission, Installing ] Transmission, Installing.

- Fill the DSG(R) oil. Refer to => [ DSG(R) Oil, Draining and Filling ] DSG(R) Oil, Draining and Filling.

Do not start the engine if there is no oil in the transmission.

- After installing the transmission, perform the basic setting using the Guided Functions. Refer to the vehicle diagnostic tester.