Direct-Shift Transmission General Information
Direct-Shift Transmission General Information
Transmission construction and function
You can learn more about the functions in 851403 Direct Shift Automatic Transmission 02E.
Always make sure that no dirt enters an open transmission. Dirt entering can cause a transmission malfunction especially with open Direct Shift Gearbox (DSG) Mechatronic (J743) and/or oil pump.
• If caps are removed from transmission or transmission has no oil, do not run engine and do not tow vehicle.
• Always clean connection points and vicinity and then loosen.
• When installing transmission, make sure alignment sleeves are correctly seated between engine and transmission.
• Place removed parts on a clean surface. Cover parts to prevent soiling. Use sheeting or paper. Use lint-free cloths only!
• Only install clean parts: Remove packing from replacement parts immediately prior to installation and not before.
• Carefully cover or plug unpacked components if repairs cannot be performed immediately.
Tools
A complete list of special tools and equipment used in this repair information is listed before each repair description and in Special Tools.
With smaller bolts with minimal tightening torques, uncertainties often exist. Torque wrench 2 to 10 Nm (V.A.G 1783) can be used for these bolts.
Gaskets, Seals
• Always replace O-rings, gaskets and seals.
• Before installing a radial shaft seal, coat sealing lips and space between with grease (G 052 128) and outer circumference with DSG oil.
• Use only DSG oil. Other lubricants cause malfunctions.
• Open side of seal faces oil.
• After installation, change direct-shift transmission oil and filter and adjust oil level --> [ Transmission, Changing Oil, Filter and Adjusting Oil Level ] Transmission, Changing Oil, Filter and Adjusting Oil Level.
DSG Oil
Shake before opening.
CAUTION!
Be cautious when dealing with oil. Dispose of drained oil properly. Consider this: One drop of oil can contaminate 1000 liters of drinking water.
Oil and filter
The oil does not lubricate just the transmission.
The oil also transports the finest differential abrasive parts in both filters, ensures lubricating film does not wear off differential tooth flanks and at the same time, it acts as a gear selector pressure medium to enable it to perform its functions.
It also seals selector lever and helps synchronizer rings when shifting gears. It conserves and transports heat, minimizes noise, oil has many tasks. The DSG oil meets some very high demands!
To maintain this degree of performance, the filter on the transmission must also be replaced at each oil change.
Oil and troubleshooting oil level check
Oil can only be missing if it has leaked from the transmission.
- Check where oil has escaped from the transmission. Repair leak first, before changing oil and direct-shift transmission filter and then readjust oil level correctly--> [ Transmission, Changing Oil, Filter and Adjusting Oil Level ] Transmission, Changing Oil, Filter and Adjusting Oil Level.
Adding oil does not correct a malfunction and does not help to find the malfunction.
The oil is obtainable as a replacement part.
Do not mix any additives with the oil, do not add other oils.
Drained oil must not be used again.
Bolts and Nuts
• Loosen and tighten bolts or nuts for securing covers and housings in diagonal sequence.
• The tightening torques stated apply to unoiled bolts and nuts.
• Clean threads of bolts that were applied with locking fluid using a wire brush. Next, insert bolts using AMV 185 100 A1 locking compound.
• Use thread tap to remove remains of locking fluid from all threaded holes in which self-locking bolts are to be installed. Otherwise there is a risk that bolts will shear the next time they are removed.
• Replace self-locking bolts and nuts.
Oil drain and inspection plug - A -
Up to transmission production date September 20, 2004, transmissions with two bolts were installed.
Then the second bolt was eliminated so that oil draining and adjusting of the oil level is done only using bolt - A -.
A plastic overflow tube is located behind this bolt (with 8 mm hex socket head, torque specification: 3 Nm). Its length determines the oil level in the transmission.
Electrical Components
You have probably received a electrical shock at one time, when touching a metal item. The reason for this is the electrostatic charge that is built up in the human body. This charge can lead to malfunctions when contacting the electrical components of the transmission and the gear selector.
- Touch a grounded object, e.g. a water pipe or a hoist, before working on the electrical components! Do not make direct contact with connector contacts.