Direct Shift Gearbox Mechatronic, Transmission Removed
Direct Shift Gearbox Mechatronic, Transmission Removed
Always make sure no dirt enters an open transmission.
Dirt entering an open transmission can cause a malfunction especially with the Direct Shift Gearbox (DSG) mechatronic and/or oil pump open.
Removing
- Remove the plug - A - near the pendulum support.
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 oil level is 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).
- Remove the overflow tube
- Drain the oil
- Install the overflow tube and tighten by hand, tightening specification: 3 Nm.
- Remove the oil filter housing and filter element
- Install the new filter element with the seat facing down and tighten the housing to 20 Nm.
- Remove both covers.
- Always replace the small oil pump cover and the bolts for the large cover.
• Touch a grounded object before touching the mechatronic. Refer to => [ Electrical Components ] General Repair Information.
- Carefully release the electrical connector using a screwdriver in the - direction of the arrow -.
- If the connector retainer breaks, replace the sensor.
Do not pull on the wire!
- Remove the electrical connector.
- Remove the wire from the lower clamp - arrow I -.
- Remove the wire from the second clamp - arrow II - and lay aside; do not kink the wire.
- Remove the bolts in a diagonal sequence beginning with bolt - 1 -.
- Replace all 10 bolts
- Remove the mechatronic.
- When working with the mechatronic, be especially careful of the long sensor arm.
CAUTION!
Never lift the mechatronic by the sensor arm or allow it to rest on the arm.
The mechatronic must be replaced if the sensor arm is damaged.
- Store the mechatronic properly.
Installing
CAUTION!
Never lift the mechatronic by the sensor arm or allow it to rest on the arm.
The mechatronic must be replaced if the sensor arm is damaged.
- Before installing, check whether the transmission input speed (RPM) sensor and the clutch oil temperature sensor are installed.
- Replace both seals - arrows - if the old mechatronic is being reinstalled.
- Lubricate the seals with DSG oil (G 052 182).
A new mechatronic already has new seals.
- Carefully place the mechatronic on the alignment pins - arrow - and ensure the sensor arm finds its installed position.
- Do not pinch the wire.
- Replace all 10 bolts
- Install all the bolts by hand.
- Tighten all 10 bolts in a diagonal sequence to 5 Nm, then tighten an additional 90° in the same sequence, beginning with bolt - 1 -.
- Install the wire for the transmission input speed (RPM) sensor and clutch oil temperature sensor first into second clamp - II - and then into the first clamp - I -.
- Install the electrical connector onto the mechatronic.
- Always replace the small oil pump cover and the bolts for the large cover.
- Replace the large cover seal.
- Tighten the cover bolts in a diagonal sequence to 10 Nm.
After installing the transmission
- Fill the oil without replacing the filter. Refer to => [ Oil Filter, Changing and Oil Level, Adjusting ] 02E Transmission (Direct Shift Gearbox).
- Perform a basic measurement on the mechatronic.