Direct Shift Gearbox (DSG) Transmission Mechatronic (J743)
Direct Shift Gearbox (DSG) Transmission Mechatronic (J743)
Special tools, testers and auxiliary items required
• Release Tool (T10465)
• Assembly Pin (T40199)
Removing
Risk of transmission damage.
• Do not run engine or tow the vehicle with the oil pan removed or without transmission fluid.
• General repair instructions, refer to => [ Repair Information ] 02EA (S-Tronic) Transmission.
• Observe cleanliness rules when working on transmissions, refer to => [ Clean Working Conditions ] 02EA (S-Tronic) Transmission.
- Remove the ATF pan. Refer to => [ Oil Pan ] 02EA (S-Tronic) Transmission.
- Remove the fan shroud.
On Vehicles with a Lower Coolant Hose on the Left Side:
Risk of burning due to hot steam and hot coolant.
• When the engine is warm, the cooling system is under pressure.
• Reduce pressure by covering coolant expansion tank cap with cloths and carefully opening.
- Drain the coolant.
- Remove the lower coolant hose - 1 -.
All Vehicles:
Risk of destroying Mechatronic with electrostatic discharge.
• Do not touch contacts in connector with hands.
- To discharge electrostatic, touch vehicle ground with hand (without glove).
Risk of damaging electrical wire.
• Do not pull on electrical wire.
- Disconnect the connector - 1 - from the transmission input speed sensor (G182) and clutch oil temperature sensor (G509) using (T10465) - arrow -.
• If electrical wire is damaged, input speed sensor and clutch oil temperature sensor must be replaced.
- First remove the line from lower clamp - arrow I -.
- Remove the electric wire from the clip - arrow II - and move it to the side. Be careful not to bend it.
- Remove the bolts in the following sequence: - 1 to 10 -.
Risk of damaging the Mechatronic.
• After removing the bolts from the mechatronic, do not remove it.
- Remove the bolts in the following sequence: - 1 to 10 -.
Risk of damaging the Mechatronic.
• Without the (T40199) , the long sensor arm of the mechatronic will be damaged during removal.
- Attach 3 threaded holes for the bolts of the mechatronic for each (T40199) , as shown in the image.
• The illustration shows the installation position with the cover removed for the oil pump.
• The cover for the oil pump must not be removed for this work.
• The long sensor arm - B - of the Direct Shift Gearbox (DSG) Transmission Mechatronic (J743) may not be damaged.
- Carefully remove DSG transmission Mechatronic from the (T40199).
Risk of damaging the Mechatronic.
• The tabs - arrow 2 - on the sensor arm - B - can break off.
• Do not lift the Mechatronic by sensor arm or lay it on arm.
• If sensor arm is damaged, the Mechatronic must be replaced.
- Store Mechatronic properly.
Installing
Install in reverse order, paying attention to the following:
Tightening specifications, refer to:
• => [ Oil Pan, Mechatronic and Transmission Fluid Pump Overview ] Oil Pan, Mechatronic and Transmission Fluid Pump Overview
• => [ - Tightening Specification and Sequence ] Oil Pan, Mechatronic and Transmission Fluid Pump Overview
- Remove all the caps on the new Mechatronic if replacing the DSG transmission Mechatronic.
• Replace the bolts for the DSG transmission Mechatronic.
• Replace O-rings - arrows - on DSG transmission Mechatronic connector.
• If DSG transmission Mechatronic is replaced, O-rings are contained in replacement part delivery package.
- Carefully insert DSG transmission Mechatronic in transmission housing through the (T40199).
• The illustration shows the installation position with the cover removed for the oil pump.
• The cover for the oil pump must not be removed for this work.
• The long sensor arm - B - of the DSG transmission Mechatronic may not be damaged.
- Make sure the alignment pin - A - in the transmission housing - arrow 1 - and the sensor arm - B - in the guide - arrow 2 - fit correctly on the transmission housing.
- Carefully position the Mechatronic on the alignment pins and make sure the sensor arm moves into its installed position.
• Electrical wire to input speed sensor and clutch oil temperature sensor must not be pinched.
- Remove the assembly pin (T40199).
- Tighten the DSG transmission Mechatronic bolts. Refer to => [ - Tightening Specification and Sequence ] Oil Pan, Mechatronic and Transmission Fluid Pump Overview.
- First engage electrical wire in upper retaining tab - arrow II - and then in lower tab - arrow* I -.
- Connect connector to input speed sensor and clutch oil temperature sensor and check connector engagement.
- Install the oil pan. Refer to => [ Oil Pan ] 02EA (S-Tronic) Transmission.
- Install DSG transmission Mechatronic electrical connector and lock retainer by turning.
- Install the particulate fan shroud.
Risk of damage to the engine through overheating.
• If the coolant was drained, only fill up the transmission fluid and do not start the engine yet.
• First start the motor when the coolant is filled for the engine cooling.
- Fill the transmission with fluid. Refer to => [ Transmission Fluid, Replacing or Filling after Repair ] Transmission Fluid, Replacing or Filling After Repair.
On Vehicles with a Lower Coolant Hose on the Left Side:
- Install coolant hose under - 1 -.
- Fill coolant system.
All vehicles:
- Start the engine and run at idle.
- Press brake and shift through all selector lever positions "P, R, N, D, S" at idle, retaining each position for at least 3 seconds.
- Move the selector lever into "P".
- Transmission fluid level, checking and filling, refer to => [ Transmission Fluid, Checking and Filling ] Transmission Fluid, Checking and Filling.
- Perform a basic setting using the vehicle diagnostic tester.