0B5A Automatic Transmission
DSG Mechatronic
Special tools, testers and auxiliary items required
• Oil Collecting and Extracting Device (V.A.G 1782)
Removing
• Transmission installed.
CAUTION!
There is a risk of damaging the transmission.
• Do not start the engine when there is no ATF in the transmission and the Direct Shift Gearbox (DSG) Mechatronic (J743) is removed.
• General repair notes. Refer to => [ Repair Information ] Repair Information.
• Rules for cleanliness when working on the DSG transmission. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
• DSG Transmission 0B5 Information. Refer to => [ Transmission Control Module Safety Functions ] Transmission Control Module Safety Functions.
- Place selector lever in position "P".
CAUTION!
Risk of destroying electronic components when disconnecting the battery.
• Follow the steps when disconnecting the battery.
- Switch ignition off and remove ignition key.
- Disconnect Ground (GND) cable - arrow - from the battery terminal.
CAUTION!
There is a risk of destroying the transmission control module (Mechatronic) with static discharge.
• Always discharge "static electricity". Do this by touching a grounded object, e.g. vehicle ground, the vehicle or the hoist.
• Do not touch contacts in transmission connector with hands.
- Disconnect electrical connector on transmission by rotating screw connections counterclockwise - arrow -.
- Remove bolt - 1 -.
- Turn the connector housing - 2 - counter-clockwise - arrow - and remove it.
- Remove bolts - arrows - and pull out the ATF pipe connection slightly.
• The connection with the ATF pipe removed is shown in the illustration.
- Remove ATF oil pan. Refer to => [ Automatic Transmission Fluid Oil Pan ] 0B5A Automatic Transmission.
- Place Used Oil Collection and Extraction Device (V.A.G 1782) under transmission.
- Carefully pull the ATF filter to the rear and off the mechatronic - arrow -.
CAUTION!
There is a risk of destroying the transmission control module (Mechatronic) with static discharge.
• Always discharge "static electricity". Do this by touching a grounded object, e.g. vehicle ground, the vehicle or the hoist.
• Do not touch contacts in transmission connector with hands.
- Disconnect the connector by pulling the locking clip - arrow 1 - and pushing the release downward - arrow 2 -.
- Remove bolts - 1 through 6 -.
CAUTION!
Risk of damaging mechatronic.
• Only the bolts with the painted bolt head may be loosened.
• If other bolts are loosened, this may affect the function of the mechatronic unit or it may come apart.
• The sealing surface must not be damaged.
• The mechatronic fits partially inside the transmission.
• If the mechatronic must be removed, then a second technician will be needed to keep it from falling. Another alternative, the bolts - 1 - and - 2 - can be installed slightly to hold the mechatronic in place while it is being removed.
- Remove the mechatronic.
CAUTION!
Danger of damaging the sensor on the back side of the mechatronic.
• Lay the mechatronic with the bolt head side facing down only.
Installing
• Tightening specifications. Refer to => [ DSG Mechatronic Assembly Overview ] Description and Operation.
• Replace the mechatronic O-rings and bolts.
• Do not bend the ATF oil pipe brackets.
- Remove bolts - arrows -.
- Remove ATF oil pipes - 1 - and - 2 -.
- Remove ATF oil pies - 3 through 5 -.
- Replace O-rings and install the ATF oil pipes.
- Tighten bolt - arrow -.
• Before installing the Direct Shift Gearbox (DSG) Mechatronic (J743) make sure all the shift forks and gear selectors are in the center position.
Adjust the shift forks:
- First check the shift positions for the shift forks - 1 through 4 - by hand.
Each shift fork has three positions:
• Gear engaged - G -
• Idle - N - (center position)
• Gear engaged - G -
- Move all 4 shift forks one time into each position - arrows - one after the other.
- After doing this, move the shift forks back into the center position - N -.
Adjust the gear selector:
CAUTION!
There is a risk of destroying the transmission control module (Mechatronic) with static discharge.
• Always discharge "static electricity". Do this by touching a grounded object, e.g. vehicle ground, the vehicle or the hoist.
• Do not touch contacts in transmission connector with hands.
• Do not pry out the plunger on the sensors.
- Place the 4 gear selectors on the back side of the mechatronic in the center position to dimension - a - by carefully pulling the pushing the gear selector in and out.
• Dimension - a - = 33.5 mm.
- Align the gear selector yokes - arrows - so that they engage into the eyes in the shift fork when being installed.
- Insert the mechatronic into the transmission housing.
• The mechatronic and its bolts must fit easily into the holes in the transmission.
• If the mechatronic does not go in easily, then it is possible that a shift fork or a gear selector is not in its center position. Check the center position and adjust if necessary.
After installing the mechatronic:
- Using a flashlight, check all the gear selectors through the opening between the mechatronic and the transmission housing.
• All 4 gear selector yokes must fit correctly in the shift fork eyes.
- Tighten the mechatronic bolts. Refer to => [ Mechatronic, tightening specification and sequence ] Description and Operation
Install in reverse order, paying attention to the following:
CAUTION!
There is a risk of destroying the transmission control module (Mechatronic) with static discharge.
• Always discharge "static electricity". Do this by touching a grounded object, e.g. vehicle ground, the vehicle or the hoist.
• Do not touch contacts in transmission connector with hands.
- Make sure the connector is correctly connected to the mechatronic.
- Install the ATF filter. Refer to => [ ATF Filter ] 0B5A Automatic Transmission.
- Install the ATF oil pan => [ Automatic Transmission Fluid Oil Pan ] 0B5A Automatic Transmission.
- Top off ATF => [ ATF, Checking Level and Correcting ] Procedures.