DSG Transmission Mechatronic -J743-, TRANSMISSION INSTALLED

Special Tools And Workshop Equipment Required 

• Torque Wrench (5-50 Nm) V.A.G 1331
• Oil Collecting and Extracting Device V.A.G 1782

Removing 

Always make sure that no dirt enters an >>open<< transmission.

Dirt entering can cause a transmission malfunction especially with a >>open<< DSG transmission Mechatronic and/or oil pump.

In regard to contaminated fluid, also observe information on changing the transmission filter. Refer to DSG TRANSMISSION FLUID .

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

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

-- Turn off the ignition and disconnect the battery ground cable. Refer to Removal and Installation .

-- Remove the noise insulation. Refer to Description and Operation .

If Present:

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

For diesel engines, refer to CHARGE AIR COOLER HOSE, DISCONNECTING AND CONNECTING .

For gas engines, refer to CHARGE AIR SYSTEM ASSEMBLY OVERVIEW , or CHARGE AIR COOLER ASSEMBLY OVERVIEW .

• Depending on the vehicle, the parts could be:
  Fig 1: Fan Shroud

  Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
• Fan shroud -arrow-
• Additional lines for the Air Conditioning (A/C) system
• Charge or cold air pipes

-- Remove the electric wires and bracket -arrows- from the large front transmission cover.

-- Disconnect the connector -1-.

-- Position the lines in the area of the cover upward and tie up.

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

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

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

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.

About 5.0 liters of fluid will drain. The oil collecting and extracting device V.A.G 1782 should remain under the transmission.

-- Reinstall the overflow tube and tighten it to 3 Nm.

-- Loosen the cover bolts -arrows- diagonally and remove them.

-- Guide the cover over the starter bolt.

-- Remove the cover and seal.

In order to have enough free space to remove the Mechatronic unit, the pendulum support can be removed.

Then the transmission can be pressed down and back slightly.

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

-- Carefully unlock the transmission input speed sensor -G182- and clutch oil temperature sensor -G509- connector with a small screwdriver -1-.

-- Press only on the release with the screwdriver -1-.

-- Do not pry.

Do not use the screwdriver as a lever.

-- Loosen the connector with the screwdriver -2-.

Be very careful. The connector locking mechanisms can break. Replace the sensor if this happens.

Do not pull on the wire.

-- Remove the connector.

-- Remove the wire from the tabs -arrows-.

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

-- 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 >>long<< sensor arm -B-.

-- Carefully move the Mechatronic unit downward.

Store the Mechatronic unit properly

Replace the Mechatronic unit if the arm gets damaged.

Installing 

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

Replace the Mechatronic unit if the arm gets damaged.

-- Carefully install the Mechatronic unit into the transmission.

The Mechatronic unit and the transmission must be the same temperature. Otherwise the alignment pins will not lock during installation.

-- Do not pinch the wire.

Make sure the wire does not get pinched.

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

-- Hold the Mechatronic unit facing up. The sensor arm must not touch the sensor wheel. (see the close up)

-- 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 into the upper, and then into the lower tab -arrows-.

-- Connect the connector.

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

-- Lubricate the O-rings with DSG transmission fluid.

A new Mechatronic unit already has new O-rings.

-- 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.

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

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

-- Install the hose between the charge air cooler and the charge air pipe, if was removed earlier. Refer to one of the following:

For diesel engines, refer to CHARGE AIR COOLER HOSE, DISCONNECTING AND CONNECTING .

For gas engines, refer to CHARGE AIR SYSTEM ASSEMBLY OVERVIEW , or CHARGE AIR COOLER ASSEMBLY OVERVIEW .

-- Reinstall any vehicle parts removed.

-- Connect the battery ground cable. Refer to Removal and Installation .

-- Do not start the engine.

-- Change the filter if the fluid is dirty.

-- Replace the DSG transmission fluid and filter. Refer to TRANSMISSION FLUID, DRAINING AND FILLING .

-- Install the noise insulation. Refer to Description and Operation .

-- Perform a basic measurement on the DSG transmission Mechatronic.