General Repair Information
General Repair Information
Tools
A complete list of special tools and workshop equipment used in this repair information can be found at the beginning of each repair procedure and at the end of each repair group.
For small fasteners with a minimal tightening specification, uncertainties often exist. Use the torque wrench (V.A.G 1783) for these fasteners.
Transmission
Always make sure no dirt can get into an open transmission. Dirt entering an open transmission, can cause a malfunction especially with a open DSG transmission Mechatronic and/or oil pump.
• Do not run the engine and do not tow the vehicle if the transmission cover is removed or if there is no DSG(R) oil inside the transmission.
• Always clean the connection points and the surrounding areas first, and then loosen them.
• When installing the transmission, make sure the alignment sleeves are correctly installed between the engine and transmission.
• Place removed parts on a clean surface and cover them so that they do not get dirty. Use foil, paper or a lint free cloth.
• Only install clean components: Only unpack replacement parts immediately prior to installation.
• Carefully cover or seal unpacked components if repairs cannot be performed immediately.
Seals
• Replace the O-rings, seals and gaskets.
• After removing O-rings and seals, always inspect the contact surfaces on the housing or shaft for burrs resulting from removal, or for other signs of damage.
• Before installing the seal, lightly oil the outer circumference and fill the space between the sealing lips - arrow - halfway with sealing grease for seal (G 052 128 A1).
• The open side of the seal point toward the fluid to be sealed in.
• Use Direct Shift Gearbox (DSG(R)) oil only. Other lubricants cause malfunctions.
• After replacing the seals, O-rings and gaskets, check the fluid level and fill if necessary. Refer to => [ Transmission Oil Level, Checking and Filling ] Transmission Oil Level, Checking and Filling.
DSG(R) Oil
Shake the container before opening it.
The DSG(R) oil is obtainable as a replacement part. For the correct part number, refer to the Parts Catalog.
The oil quality is of vital importance for transmission function.
Do not mix additives into the oil. Do not fill with a different oil.
The drained oil must not be reused again.
Be cautious when dealing with DSG(R) oil. Dispose of the drained oil properly. Bear in mind that: One drop of oil can make 600 liters (158.5 gallons) of drinking water unusable.
When To Change the Oil Filter
The filter does not need to be changed in every case.
DO NOT replace the filter if:
• The 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.
• The Mechatronic covers were leaking, the Direct Shift Gearbox (DSG(R)) clutch or oil pump were replaced.
• The transmission input speed sensor and the clutch oil temperature sensor were replaced.
The filter MUST be replaced if:
• The 60,000 km (Canada) or the 40,000 mile (US) 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 Drain and Inspection Plugs
Up to transmission production date "September 20, 2004", transmissions with two plugs were built.
Then, the second plug was eliminated so that oil draining and the level adjusting is done using only the one plug - A -.
A plastic overflow tube is located behind this plug (with a 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 the covers and housings diagonally.
• The tightening specification stated applies to non-lubricated nuts and bolts.
• Use a wire brush to clean the threads of bolts that were installed using locking fluid. Install the bolts using AMV 185 100 A1 (liquid locking fluid).
• Use a thread tap to clean all threaded holes containing self-locking bolts to remove any locking fluid residue. Otherwise the bolts could shear the next time they are removed.
• Always replace self locking nuts and bolts.
Electrical Components
You have probably received a electrical shock at one time, when touching a metal item. The reason behind this is the electrostatic charge to the human body. This charge can damage the electrical components on the transmission and the selector mechanism.
- Touch a grounded object before working on electric components. Do not touch connectors or open electronic components directly.