DSG Transmission Mechatronic -J743-, WITH TRANSMISSION REMOVED: Removing

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NOTE:

Follow the rules for clean working conditions CLEAN WORKING CONDITIONS .

General repair instructions. Refer to GENERAL REPAIR INFORMATION .

Always make sure that no dirt enters an open transmission.

Dirt entering can cause the transmission to malfunction especially if the DSG Transmission Mechatronic -J743- and/or the transmission fluid pump are open.

-- Place the Used Oil Collection and Extraction Unit SMN 372500 or Drip Tray under the transmission.

-- Remove the drain- and check plugs -arrow- and drain the transmission fluid.

Fig 1: Identifying Oil Plug

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A plastic overflow tube is located in this hole (with 8 mm hex socket head). Its length determines the oil level in the transmission.

-- Remove this overflow pipe and drain the rest of the transmission fluid.

NOTE:

Approximately 5.0 liters of transmission fluid will flow out. Leave the Used Oil Collection and Extraction Device V.A.G 1782 or the Catch Tray under the transmission.

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

-- Tighten the overflow tube to the tightening specification.

-- If it is necessary, remove filter.

Fig 2: Identifying Transmission Filter

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-- Remove the transmission cover and the transmission pump cover.

Fig 3: Locating Oil Pump Covers

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NOTE:

Always replace the transmission pump cover, the bolts for the transmission pump cover as well as the gasket and the transmission cover bolts.

-- Touch a grounded object again before touching the Mechatronic.

-- Disconnect the connectors -1- from the Transmission Input Speed Sensor -G182- and Clutch Oil Temperature Sensor -G509- using Release Tool T10465.

Fig 4: Identifying Connector -1- And Release Tool - T10465-

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NOTE:

If Release Tool T10465 is not available, the connector can be removed by carefully using two screwdrivers as follows:

Fig 5: Identifying Connector For Transmission Input Speed (RPM) Sensor G 182 With Clutch Oil Temperature Sensor G509

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Press only on the release with the screwdriver -1-. Do not use a screwdriver as a lever.

Loosen the connector -2- using a screwdriver.

Be very careful. The connector locking mechanisms can break. If this happens, the sensor must be replaced.

Do not pull on the wire.

-- Remove connector.

-- First remove line from lower clamp -arrow I-.

Fig 6: Locating Wire Clamps

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-- Then remove it from the upper clip -arrow II- and move it to the side. Do not kink line.

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

Fig 7: Direct Shift Gearbox Mounting Bolts Removal Sequence

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-- Remove the DSG Transmission Mechatronic -J743-.

Fig 8: Identifying DSG Mechatronic J743, Removal

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

CAUTION:

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

Replace the Mechatronic if the arm gets damaged.

Fig 9: Caution Mechatronic Resting On Sensor Arm

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Store Mechatronic properly.

Fig 10: Caution Handling Mechatronic

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