General Repair Information
General Repair Information
For more information about the Direct Shift Gearbox (DSG) transmission, refer to 851403The 02E Direct Shift Gearbox Design and Function.
Tools
A complete list of special tools and equipment used in this repair information is listed before each repair description and in the special tools catalog.
For smaller bolts with a minimal tightening specification, uncertainties often exist. Torque wrench (5-60 Nm) (VAG 1783) can be used on these bolts.
Transmission
Always make sure that no dirt enters an open transmission. Dirt entering can cause a transmission malfunction especially with the DSG mechatronic and/or oil pump open.
• Do not run the engine and do not tow the vehicle if the covers are removed from the transmission or there is no oil in the transmission.
• Always clean the connection points and vicinity first and then loosen and fasteners.
• When installing the transmission, make sure the alignment pins are correctly seated between the engine and transmission.
• Place parts that have been removed on a clean surface and cover.
• Do not use fluffy cloths!
• Do not use dirty film and paper.
• Only install clean components: Only unpack the replacement parts immediately prior to installation.
• Carefully cover or reseal unpacked components if the repairs cannot be performed immediately.
Gaskets and Seals
• Always replace O-rings, gaskets and seals.
• Before installing the radial shaft seal, lubricate the sealing lips and the space between them with radial shaft seal sealing grease (G 052 128 A1) and the outer circumference with DSG oil (G 052 182).
• Only use DSG oil (G 052 182) because other lubricants can cause malfunctions.
• The open side of the seal face toward the oil.
• After installation, change the oil and check the oil level, Refer to => [ Oil Filter, Changing and Oil Level, Adjusting ] 02E Transmission (Direct Shift Gearbox).
DSG Transmission Oil
Shake the bottle 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.
DSG oil (G 052 182) is available as a replacement part.
Do not mix any additives into the oil and do not add any other type oil.
Drained oil must not be used again.
Oil Function
Oil does not just lubricate the transmission.
The oil also transports the finest differential abrasive parts in both filters, ensures the lubricating film does not wear off the 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 the selector lever and helps the synchronizer rings when shifting gears. It conserves and transports warmth, minimizes noise.
To maintain this degree of performance, the filter on the transmission should be replaced during the oil maintenance service.
Oil Filter Change - Yes or No?
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 coolants 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 with clutch oil temperature sensor 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
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 these leaks first before changing the oil and then adjust the oil correctly again. Refer to => [ Oil Filter, Changing and Oil Level, Adjusting ] 02E Transmission (Direct Shift Gearbox).
Adding oil just in case does not correct a malfunction and it does not help to find the malfunction.
Oil Drain and Inspection Plug
Up to transmission production date "September 20, 2004", transmissions with two plugs were installed.
Following that, the second plug was discontinued and the oil is drained and the level checked only with the plug- A -.
The oil level in the transmission is determined with the length of the plastic overflow tube with 8 mm hex head (tightening specification 3 Nm).
Bolts and Nuts
• Loosen and tighten the cover and housing bolts or nuts in a diagonal sequence.
• The tightening specifications stated apply to non lubricated nuts and bolts.
• Clean the threads on bolts that were installed with locking compound and then insert the bolts with locking compound (AMV 185 100 A1).
• Use a thread tap to clean the locking compound residue from all the threaded holes in which self locking bolts were installed. Otherwise, there is the danger that the bolts could shear off when installed again.
• 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 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 hoist, before working on electrical components! Do not make direct contact with electrical connector contacts.