DSG Transmission Mechatronic -J743-, TRANSMISSION REMOVED

WARNING: This page is about a different variant/trim than selected.

Special Tools And Workshop Equipment Required

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

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 .

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.

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.

-- Place the oil collecting and extracting device V.A.G 1782 or a drip tray under the transmission.

-- Remove the overflow tube.

-- Drain the transmission fluid.

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

-- Tighten the overflow tube to 3 Nm.

-- If it is necessary, remove the filter.

Fig 2: Identifying Transmission Filter

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

For information on changing the filter, refer to DSG TRANSMISSION FLUID this can help when making this decision.

-- Insert the new filter with the seat facing downward 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.

Replace the seal on the large cover.

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

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

Fig 4: View Of Unlocking Speed Sensor Connector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Only press the retainer with the screwdriver -1-. Do not pry it.

Do not use the screwdriver as a lever.

-- Loosen the connector using a 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.

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

Fig 5: Locating Wire Clamps

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Diagonally loosen the bolts -1 through 10- starting with the bolt -1-.

Fig 6: Identifying DSG Mounting Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Replace all 10 bolts.

-- Remove the DSG transmission Mechatronic.

Fig 7: Removing DSG Mechatronic J743

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

CAUTION:

Never lift the Mechatronic unit by the sensor arm and never let it rest on the arm.

Replace the Mechatronic unit if the arm gets damaged.

Store the Mechatronic unit properly

Fig 8: Caution Handling Mechatronic

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Installing

CAUTION:

Never lift the Mechatronic unit by the sensor arm and never let it rest on the arm.

Replace the Mechatronic unit if the arm gets damaged.

-- Make sure the transmission input speed sensor and clutch oil temperature sensor is installed.

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Replace both O-rings for the Mechatronic unit connection if the old unit is being re-installed.

Fig 10: Identifying O-Rings On Connection Of Mechatronic

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

A new Mechatronic unit already has new O-rings.

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

-- Carefully place the Mechatronic unit on the alignment pin -arrow-. The goal is for the sensor arm to be in its installed position.

Fig 11: Carefully Placing Mechatronic On Alignment Pins

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- The sensor arm must not touch the sensor wheel. (see close up)

-- Do not pinch the wire.

Be sure not to pinch the wire.

All of the bolts -1 through 10- must be replaced.

Fig 12: Identifying Mounting Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

-- Install the transmission input speed sensor and clutch oil temperature sensor wire in the upper tab -arrow II- first. Then, install the wire in the lower tab -arrow I-.

Fig 13: Locating Wire Clamps

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Press the connector onto the Mechatronic unit.

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

Replace the seal for the large cover.

Fig 14: Locating Oil Pump Covers

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Diagonally tighten the cover bolts to 10 Nm.

After installing the transmission,

-- Fill with fluid, without replacing the filter. Refer to TRANSMISSION FLUID LEVEL, CHECKING AND ADDING .

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