DSG Transmission Mechatronic -J743-, TRANSMISSION INSTALLED

Special tools and workshop equipment 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 a 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 OIL FILTER .

The Mechatronic unit can get stuck on the alignment pins when the transmission is very warm. Let the transmission cold down.

-- Lift the vehicle, all 4 lift points for the hoist must be at the same height.

-- Move the selector lever into the "P" position.

-- Remove the noise insulation. Refer to Removal and Installation .

If present: 

-- Remove the charge air hose from between the charge air cooler and the charge air pipe. Refer to one of the following:

Gas engines, refer to [For engine(s) BPY] Description and Operation , or [For engine(s) CCTA, CBFA] Description and Operation .

• Depending on the vehicle, the parts could be:
  Fig 2: Identifying Fan Shroud

  Courtesy of VOLKSWAGEN UNITED STATES, INC.
• Fan shroud
• Additional lines for the Air Conditioning (A/C) system
• Charge air pipes

-- Disconnect the connector -1- from the Mechatronic unit.

-- Remove the two M6 nuts -arrows- and the wire bracket from the large transmission cover.

Tightening specification: 10 Nm

-- Position the wires in the area of the cover upward and secure.

-- Place the used oil collecting and extracting device -V.A.G 1782- under the transmission near the large cover.

-- Loosen the cover bolts -arrows- diagonally and remove them. Hold the cover in place while doing this.

-- Drain the oil and remove the cover and seal.

About 3 liters of oil will drain out.

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

-- Remove the pendulum support to transmission bolts -2 and 3-.

The transmission can now be pressed down slightly to remove the Mechatronic unit.

Before handling the Mechatronic unit, touch a grounded object. Refer to ELECTRICAL COMPONENTS .

-- Disconnect the connector -1- from the transmission input speed sensor -G182- and clutch oil temperature sensor -G509- using the release tool -T10465-.

-- First, remove the wire from lower clip -arrow I-.

-- Then remove the wire from the upper clip -arrow II- and lay it aside. Do not kink the wire.

-- Loosen and remove the bolts -1 through 10- in the specified sequence.

-- Carefully pull the Mechatronic unit out of transmission housing far enough until the sensor arm -B- on the rear side is no longer located in the transmission housing.

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

-- Carefully move the Mechatronic unit downward.

Replace the Mechatronic unit if the sensor arm gets damaged.

Installing 

Before handling the Mechatronic unit, touch a grounded object again. Refer to ELECTRICAL COMPONENTS .

-- Carefully install the Mechatronic unit into the transmission.

-- 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.

-- Make sure the Mechatronic unit is installed correctly.

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

-- Tighten the bolts to 5 Nm + 90° (1/4) additional turn, in the specified sequence.

-- Hook the wire -A- first under the upper, and then under the lower clips -arrows-.

-- Connect the connector.

-- Replace both O-rings if reinstalling the old Mechatronic unit.

A new Mechatronic unit already has new O-rings.

-- Coat the O-rings with DSG R transmission oil.

-- Clean the cover seal and transmission sealing surfaces.

-- Make sure the seal fits correctly.

-- Place the cover over the Mechatronic unit without pinching any wires.

-- Install new bolts -arrows- and tighten them to 10 Nm diagonally and in several steps.

-- Set the new oil pump cover -A- in place and tighten the bolts -arrows- in a diagonal sequence to 8 Nm in stages.

-- Install the wire bracket to the cover and then tighten the nuts to 10 Nm.

-- Connect the connector to the Mechatronic unit and engage the retainer by turning.

-- If present: Install the charge air hose between the charge air cooler and charge air pipe. Refer to one of the following:

Gas engines, refer to [For engine(s) BPY] Description and Operation , or [For engine(s) CCTA, CBFA] Description and Operation .

-- Reinstall any vehicle parts which were removed.

-- Do not start the engine.

-- Change the filter if the oil was dirty. Refer to OIL FILTER .

-- Connect the vehicle diagnostic tester.

-- Place the used oil collecting and extracting device -V.A.G 1782- under the transmission near the plug.

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

-- Measure the length of the pipe, dimension -a- before installing the adapter for oil filling -VAS 6262 A- to the oil bottle and shorten the pipe, if necessary. Refer to MODIFYING THE ADAPTER FOR OIL FILLING VAS 6262 A .

-a- = 210 mm

-- Install the adapter for oil filling -VAS 6262 A- into the plug hole hand tight.

-- Shake the bottles before opening.

-- Fill with 3 liters of transmission oil.

-- To change containers, close the shut-off lever or hold the adapter for oil filling -VAS 6262 A- higher than the transmission.

Start the engine and check the fluid level. The adapter for oil filling -VAS 6262 A- remains installed.

-- Check the fluid level and fill if necessary. Refer to TRANSMISSION OIL LEVEL, CHECKING AND FILLING .

-- Install the noise insulation. Refer to Removal and Installation .

-- Perform a basic setting.