DSG Transmission Mechatronic -J743-, TRANSMISSION REMOVED

Special tools and workshop equipment required 

• Release Tool -T10465-

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 information on changing the oil filter. Refer to WHEN TO CHANGE THE OIL FILTER .

Removing 

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

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

A plastic overflow tube is located in this hole (with a 8 mm hex socket head, tightening specification: 3 Nm). Its length determines the oil level in the transmission.

-- Remove the overflow tube.

-- Drain the oil.

In regard to >>contaminated oil<<, also observe information on changing the oil filter. Refer to WHEN TO CHANGE THE OIL FILTER .

-- Install the overflow tube; tightening specification: 3 Nm.

-- If it is necessary, remove the oil filter.

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

For information on changing the oil filter, refer to WHEN TO CHANGE THE OIL FILTER , this can help when making that decision.

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

-- After repairing, you do not have to change the filter again when filling the oil.

-- Remove both the small and large covers.

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

Replace the seal on the large cover.

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 the lower clip -arrow I-.

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

-- Remove the bolts diagonally. Start with the bolt -1-.

Replace all 10 bolts.

-- Remove the Mechatronic unit.

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

Replace the Mechatronic unit if the sensor arm gets damaged.

Mechatronic, Installing 

Replace the Mechatronic unit if the sensor arm gets damaged.

-- Make sure the transmission input speed sensor and clutch oil temperature sensor are installed before installing the Mechatronic unit.

-- 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.

-- Carefully mount the Mechatronic unit onto the alignment pins -arrow-. The goal is for the sensor arm to be in its installed position.

-- Do not pinch the wire.

Make sure the wire does not get pinched.

Replace all 10 bolts.

-- Install all the bolts by hand.

-- Tighten all 10 bolts diagonally to 5 Nm. Then tighten them an additional 90° (1/4) turn following the same sequence. Start with the bolt -1-.

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

-- Press the connector onto the Mechatronic unit.

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

-- Install the 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 and in stages to 8 Nm.

After installing the transmission.

-- Check the fluid level and fill as necessary. Refer to DSG R OIL, DRAINING AND FILLING .

-- Connect the vehicle diagnostic tester.

-- Perform a basic setting.