MECHATRONIC, Transmission Removed

WARNING: This page is about a different car, the 2008 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.

Always make sure no dirt enters an open transmission.

Dirt entering an open transmission can cause a malfunction especially with the Direct Shift Gearbox (DSG) mechatronic and/or oil pump open.

Removing

-- Remove the plug -A- near the pendulum support.

Fig 1: Identifying Oil Drain And Inspection Plug

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Up to transmission production date "September 20, 2004", transmissions with two plugs were installed.

Following that, the second plug was discontinued and the oil is drained and the oil level is checked only with the plug -A-.

The oil level in the transmission is determined with the length of the plastic overflow tube with 8 mm hex head (tightening specification: 3 Nm).

-- Remove the overflow tube

-- Drain the oil

-- Install the overflow tube and tighten by hand, tightening specification: 3 Nm.

-- Remove the oil filter housing and filter element

Fig 2: Identifying Transmission Filter

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the new filter element with the seat facing down and tighten the housing to 20 Nm.

-- Remove both covers.

Fig 3: Locating Oil Pump Covers

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

NOTE:

Touch a grounded object before touching the mechatronic. Refer to GENERAL REPAIR INFORMATION => Electrical Components .

-- Carefully release the electrical connector using a screwdriver in the -direction of the arrow-.

Fig 4: Releasing Connector Using A Screwdriver

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- If the connector retainer breaks, replace the sensor.

Do not pull on the wire!

-- Remove the electrical connector.

-- Remove the wire from the lower clamp -arrow I-.

Fig 5: Locating Wire Clamps

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the wire from the second clamp -arrow II- and lay aside; do not kink the wire.

-- Remove the bolts in a diagonal sequence beginning with bolt -1-.

Fig 6: Identifying DSG Mounting Bolts

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-- Replace all 10 bolts

-- Remove the mechatronic.

Fig 7: Removing DSG Mechatronic J743

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- When working with the mechatronic, be especially careful of the long sensor arm.

CAUTION:

Never lift the mechatronic by the sensor arm or allow it to rest on the arm.

The mechatronic must be replaced if the sensor arm is damaged.

-- Store the mechatronic properly.

Fig 8: Caution Handling Mechatronic

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Installing

CAUTION:

Never lift the mechatronic by the sensor arm or allow it to rest on the arm.

The mechatronic must be replaced if the sensor arm is damaged.

-- Before installing, check whether the transmission input speed (RPM) sensor and the clutch oil temperature sensor are installed.

Fig 9: Locating Transmission Input Speed Sensor G182 And Clutch Oil Temperature Sensor G509

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-- Replace both seals -arrows- if the old mechatronic is being reinstalled.

Fig 10: Identifying O-Rings On Connection Of Mechatronic

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-- Lubricate the seals with DSG oil G 052 182.

A new mechatronic already has new seals.

-- Carefully place the mechatronic on the alignment pins -arrow- and ensure the sensor arm finds its installed position.

Fig 11: Carefully Placing Mechatronic On Alignment Pins

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Do not pinch the wire.

-- Replace all 10 bolts

Fig 12: Identifying Mounting Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install all the bolts by hand.

-- Tighten all 10 bolts in a diagonal sequence to 5 Nm, then tighten an additional 90° in the same sequence, beginning with bolt -1-.

-- Install the wire for the transmission input speed (RPM) sensor and clutch oil temperature sensor first into second clamp -II- and then into the first clamp -I-.

Fig 13: Locating Wire Clamps

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the electrical connector onto the mechatronic.

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

-- Replace the large cover seal.

Fig 14: Locating Oil Pump Covers

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Tighten the cover bolts in a diagonal sequence to 10 Nm.

After installing the transmission

-- Fill the oil without replacing the filter. Refer to OIL FILTER, CHANGING AND OIL LEVEL, ADJUSTING .

-- Perform a basic measurement on the mechatronic.