General Repair Information
General Repair Information
Tools
A list of special tools and workshop equipment required for repair procedures in this repair information can be found at the start of each repair procedure and in the special tools catalog.
With smaller fasteners with a minimal tightening specification, uncertainties often exist. Use torque wrench (5- 60 Nm) (V.A.G 1783) for these fasteners.
Transmission
Always make sure that no dirt enters an open transmission. Dirt entering can cause a transmission malfunction especially with a open DSG Mechatronic unit (J743) and/or oil pump.
• If a cover is removed from the transmission or the transmission is without oil, do not run the engine and do not tow the vehicle.
• Always clean connection points and vicinity first and then loosen.
• When installing the transmission, make sure centering sleeves are correctly seated between engine and transmission.
• Place removed parts on a clean surface and cover them so they do not become contaminated. Use foil or paper. Use lint free cloths only!
• Only install clean components. Install replacement parts immediately after removing them from their packaging.
• Carefully cover or plug unpacked components if repairs cannot be performed immediately.
Seals
• No matter what kind of seals they are, they must always be replaced.
• Before installing a radial shaft seal, coat the sealing lips and the space between with grease (G 052 128) and the outer circumference with DSG oil.
• Use DSG oil only. Other lubricants cause malfunctions.
• The open side of the radial shaft seals faces towards the oil.
• After installation, change the oil and adjust the oil level. Refer to => [ Oil Filter and Oil Level, Changing and Adjusting ] Service and Repair.
DSG Oil
Shake before opening.
The oil is obtainable as a replacement part.
The oil quality is of vital importance for transmission function.
Do not use any additives. Do not fill with a different fluid.
Drained oil must not be reused again.
CAUTION!
Be cautious when dealing with oil. Dispose of drained oil properly. Remember - one drop of oil contaminates 600 liters of drinking water.
Oil Function
Oil does not just lubricate the transmission.
The oil also transports the finest differential abrasive parts in both filters. The oil makes sure the lubricating film does not wear off the differential tooth flanks. At the same time, it acts as a switch valve pressure medium to enable it to perform its functions.
It also seals the selector lever and helps the synchronizer rings when shifting gears. The oil conserves and transports warmth and minimizes noise. The fluid performs many functions. The DSG oil meets very high demands!
To maintain this degree of performance, the filter on the transmission should be replaced during the oil maintenance service.
When To Change Oil Filter
The oil filter does not need to be changed in every case.
Do not change the filter if:
• The transmission oil cooler or its O-rings were replaced and no coolant has gotten into the oil.
• The selector shaft seal was replaced.
• The flange or stub shaft seal was replaced.
• Leaking Mechatronic covers, multi-plate clutch or oil pump were replaced.
• The Transmission input speed (RPM) sensor (G182) with clutch oil temperature sensor (G509) was replaced.
The filter must be replaced if:
• The 60,000 km maintenance interval was reached.
• Coolant has entered the oil.
• Metal shavings were found in the oil.
• The clutch is burned or has a mechanical fault.
Oil and Oil Level Troubleshooting
The oil cannot disappear without a trace.
Oil can only be missing if it has leaked from the transmission.
Transmission Lubricated
- Check on where the oil has leaked from the transmission. Repair this leak first. Fill with new oil and check the level. Refer to => [ Oil Filter and Oil Level, Changing and Adjusting ] Service and Repair.
Filling the fluid just in case does not correct a malfunction. It does not help to find the malfunction and it gives you a false sense of security.
Oil Drain and Inspection Plug - A -
Up to transmission production date "September 20, 2004", transmissions with two plugs were installed.
Then the second plug was eliminated so that oil draining and adjusting of the oil level is done using only plug - A -.
A plastic overflow tube is located behind this plug (with 8 mm hex socket head, tightening specification: 3 Nm). Its length determines the oil level in the transmission.
Bolts and Nuts
• Loosen or tighten bolts and nuts for covers or housings diagonally.
• The tightening specification stated apply to non-lubricated nuts and bolts.
• Clean the threads of the bolts that were applied with locking fluid using a wire brush. Next, insert bolts using locking compound (AMV 185 100 A1).
• All threaded bores in which self locking bolts are threaded must be cleaned of remaining locking fluid using a tap. Otherwise there is a risk that the bolts will shear the next time they are removed.
• Replace self locking bolts and nuts.
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, for example, a water pipe or a hoist, before working on electrical components! Do not make direct contact with connector contacts.