DSG Transmission MECHATRONIC -J743-: Installing

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Fig 1: Identifying Mechatronic Pipes & O-rings

Courtesy of AUDI OF AMERICA, LLC

Tightening specifications, refer to DSG TRANSMISSION MECHATRONIC -J743- OVERVIEW .

NOTE:

Replace the Mechatronic O-rings and bolts.

Do not bend the ATF oil pipe brackets.

-- If equipped: Remove the bolt -arrow-.

-- Remove ATF pressure pipes (clutch pressure) -1 and 2-.

NOTE:

The ATF pressure pipes (clutch pressure) -1 and 2- in transmissions for the new version are a single unit and made out of plastic. In this case, the ATF pressure pipe (clutch pressure) must be replaced. There is no bolt -arrow- and no bracket for the ATF pressure pipe.

-- For metal ATF pressure pipes (coupling pressure): Replace the O-rings on the ATF pressure pipes -1 and 2-.

-- For plastic ATF pressure pipes (coupling pressure): Replace the ATF pressure pipes -1 and 2-.

-- Remove the ATF pipes -3 through 5-.

NOTE:

The ATF pipes -3 through 5- in transmissions for the new version are a single unit and made out of plastic. In this case, the ATF pipes must be replaced.

-- Metal ATF pipe: replace the O-rings on the ATF pipes -3 through 5-.

-- Plastic ATF pipes: replace ATF pipes -3 through 5-.

-- Coat all of the O-rings with ATF.

-- Insert all of the ATF pipes -1 through 5- again.

-- If equipped: Tighten the bracket and the bolt -arrow-.

NOTE:

Make sure all shift forks and gear positions are in the center position before installing the DSG transmission Mechatronic --.

Adjust Shift Forks

Fig 2: Identifying Shift Forks

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-- First check the shift positions for the shift forks -1 through 4- by hand.

Each shift fork has three positions:

-G- is engaged
Idle -N- (center position)
-G- is engaged

-- Move all four shift forks one time into each position -arrows- one after the other.

-- After doing this, move the shift forks back into the center position -N-.

Adjust Gear Selector

Fig 3: Locating Mechatronic Identification

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CAUTION:

There is a risk of destroying the transmission control module (Mechatronic) with static discharge.

Always "discharge" the static electricity. Do this by touching a grounded object, for example vehicle ground, the vehicle or the hoist.
Do not touch contacts in the transmission connector with hands.
Do not pry out the plunger on the sensors.

The gear shifter must be adjusted differently depending on the date of manufacture of the Mechatronic.

The date of manufacture is located only on the Mechatronic identification -arrow-.

The Mechatronic identification consists of:

Mechatronic identification				Example "L31B1138"
L	31	B1	138	Example "L31B1138"
L				Year of manufacture: L = 2010 K = 2009 J = 2008... etc.
	31			Calendar week in the year of manufacture
		B1		Manufacturer day shift identification: Monday: Shift 1 = A1, Shift 2 = B1, Shift 3 = C1 Tuesday: Shift 1 = D1, Shift 2 = E1, Shift 3 = F1 Wednesday: Shift 1 = G1, Shift 2 = H1, Shift 3 = I1... etc.
			138	Running manufacturing number of the shift per day, here, the 138th Mechatronic from shift B1

The gear positions must be adjusted to a different adjustment value from Mechatronic "L31B1138".

NOTE:

A Mechatronic with the identification. "L31A1140" was built before Mechatronic "L31B1138" because it was built by the 1st shift (A1) on a Monday.

A Mechatronic with the identification "L31C1009" was built after Mechatronic "L31B1138" because it was built by the 3rd shift (C1) on Monday.

-- Move the gear position back and forth and set the 4 gear positions on the back of the Mechatronic in the center position to dimension -a-.

Fig 4: Identifying Mechatronic Center Position Dimensions

Courtesy of AUDI OF AMERICA, LLC

For Mechatronic with identification through "L31B1137" :

-a- = 28 mm

For Mechatronic with identification from "L31B1137" :

-a- = 32 mm

-- Align the gear selector yokes -arrows- so that they engage into the eyes in the shift fork when being installed.

Fig 5: Aligning Gear Selector Yokes

Courtesy of AUDI OF AMERICA, LLC

-- Insert the Mechatronic into the transmission housing.

Fig 6: Identifying Mechatronic, Tightening Sequence

Courtesy of AUDI OF AMERICA, LLC

The Mechatronic and its bolts must fit easily into the holes in the transmission.
If the Mechatronic does not go in easily, then it is possible that a shift fork or a gear selector is not in its center position. Check the center position and adjust if necessary.

After installing the Mechatronic:

Fig 7: Checking Gear Selector Yoke Position

Courtesy of AUDI OF AMERICA, LLC

-- Using a flashlight, check all the gear selectors through the opening between the Mechatronic and the transmission housing.

All four gear selector yokes must fit correctly in the shift fork eyes.

-- Tighten the Mechatronic bolts. Refer to Figure.

Install in reverse order, paying attention to the following:

CAUTION:

There is a risk of destroying the transmission control module (Mechatronic) with static discharge.

Always "discharge" the static electricity. Do this by touching a grounded object, for example vehicle ground, the vehicle or the hoist.
Do not touch contacts in the transmission connector with hands.

-- Make sure the connector is correctly connected to the Mechatronic.

-- Install the ATF filter. Refer to ATF SUCTION FILTER .

-- Install the ATF pan. Refer to AUTOMATIC TRANSMISSION FLUID OIL PAN .

Transmission Removed

-- Install the transmission, refer to Removal and Installation

Transmission Installed

-- Fill the ATF, refer to General Information .

After replacing the DSG transmission Mechatronic --, the corresponding "Guided Functions" must be performed using the vehicle diagnostic tester, refer to General Information .