General Repair Information: Notes

For more information about the Direct Shift Gearbox (DSG) transmission, refer to 851403 The 02E Direct Shift Gearbox Design and Function.

Tools

A complete list of special tools and equipment used in this repair information is listed before each repair description.

For smaller bolts with a minimal tightening specification, uncertainties often exist. Torque wrench (5-60 Nm) VAG 1783 can be used on these bolts.

Transmission

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

• Do not run the engine and do not tow the vehicle if the covers are removed from the transmission or there is no oil in the transmission.
• Always clean the connection points and vicinity first and then loosen and fasteners.
• When installing the transmission, make sure the alignment pins are correctly seated between the engine and transmission.
• Place parts that have been removed on a clean surface and cover.
• Do not use fluffy cloths!
• Do not use dirty film and paper.
• Only install clean components: Only unpack the replacement parts immediately prior to installation.
• Carefully cover or reseal unpacked components if the repairs cannot be performed immediately.

Gaskets and Seals

Fig 1: Identifying Oil Seals Sealing Lips

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

• Always replace O-rings, gaskets and seals.
• Before installing the radial shaft seal, lubricate the sealing lips and the space between them with radial shaft seal sealing grease G 052 128 A1 and the outer circumference with DSG oil G 052 182.
• Only use DSG oil G 052 182 because other lubricants can cause malfunctions.
• The open side of the seal face toward the oil.
• After installation, change the oil and check the oil level, Refer to OIL FILTER, CHANGING AND OIL LEVEL, ADJUSTING .