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Elsa online. ElsaWin. ElsaWeb. VWPower transmission6-speed dual clutch gearbox 02E Volkswagen R GmbHGearbox mechanics;operation; construction;diff.Mechatronic unitRemoving and installing mechatronic unitRemoving and installing mechatronic unit for dual clutch gearbox J743; gearbox removed

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Removing and installing mechatronic unit for dual clutch gearbox -J743-, gearbox removed
Special tools and workshop equipment required
    
t  Used oil collection and extraction unit -V.A.G 1782-
   W00-11205
t  Release tool -T10465-
t  Not illustrated: Torque wrench -V.A.G 1331-
Always make sure that no dirt can enter an »open« gearbox. In particular, dirt entering an »exposed« mechatronic unit and/or oil pump can lead to gearbox failure.
Removing
–  Position used oil collection and extraction unit -V.A.G 1782- or a drip tray under gearbox.
   W00-10969
–  Remove oil drain and inspection plug -arrow- and drain gearbox oil.
A plastic overflow tube (with 8 mm hexagon socket head bolt, specified torque 3 Nm) is located in this hole. Its length determines the oil level in the gearbox.
–  Remove this overflow pipe and drain remaining gear oil.
  Note
About 5.0 l of gear oil will flow out. Leave used oil collection and extraction unit -V.A.G 1782- or drip tray under gearbox.
–  Screw in overflow pipe and tighten.
–  Change gearbox oil filter, if necessary → Chapter.
   S30-0195
–  Loosen bolts -arrows- of sump diagonally and remove them. Then remove sump.
  Note
The gasket and the bolts of the sump must always be renewed.
   A37-0672
–  Remove bolts -arrows- and remove oil pump cover -A-.
  Note
The oil pump cover and the oil pump bolts must always be renewed.
Touch an earthed object before touching the mechatronic unit.
   A37-0670
–  Release connector -1- of gearbox input speed sender -G182- and clutch temperature sender -G509- using release tool -T10465-.
   N34-11779
–  First pull line out of lower clip -arrow I-.
–  Then remove it from upper clip -arrow II- and lay to side. Do not kink line.
   N34-10519
–  Remove securing bolts -1 … 10- diagonally. Start with bolt -1-.
All 10 -securing bolts- must be renewed.

   
–  Remove mechatronic unit.
When handling mechatronic unit, pay special attention to the »long« sender arm.
   N34-10523
Laying mechatronic unit to side properly

  Caution
Never lift mechatronic unit on »sender arm« or lay it on arm.
    
If »arm« is damaged, mechatronic unit must be renewed.
Installing
   N34-10525
–  Before installation, make certain that gearbox input speed sender -G182- with oil temperature sender in multi-plate clutch -G509- is installed → Chapter.
   N34-10515
–  Renew both -O-rings- at connection for mechatronic unit if you refit an »old« mechatronic unit again.
Of course a »new« mechatronic unit already has »new« O-rings.
–  Moisten O-ring with DSG transmission oil.
   N34-10527
–  Carefully set mechatronic unit on dowel pin -arrow-. Ensure that »sender arm« locates in its -fitting position-.
–  Sender arm is not allowed to strike sender wheel.

–  Do not pinch wiring.
    
All securing bolts -1 … 10- must be renewed.
–  First screw in bolts -1 … 10- by hand.
–  Tighten bolts -1 ... 10- in the sequence indicated. Specified torque: → Fig.

   
–  First engage wiring for gearbox input speed sender -G182- with oil temperature sender in multi-plate clutch -G509- into upper clip -arrow II-. Then into lower clip -arrow I-.
–  Press connection onto mechatronic unit.
–  Clean sump gasket and sealing surface on gearbox.
–  Ensure proper seating of seal.
   N34-10519
–  Fit sump -A- over mechatronic unit, ensuring that no wiring is trapped in the process.
–  Insert new bolts -arrows- and tighten diagonally in several stages.
   A37-0672
–  Install new oil pump cover -A-. Insert new bolts -arrows- and tighten diagonally in several stages.
–  Installing gearbox → Chapter.
After installing gearbox
–  Fill with gear oil → Chapter.
–  Conduct basic adjustment of mechatronic unit for dual clutch gearbox -J743-.
  Note
Recalibrate the immobiliser after installing a »new« mechatronic unit.
Specified torques
t  → Chapter „Assembly overview - mechatronic unit“
   A37-0670

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