General Repair Information: Notes

For more information about the Direct Shift Gearbox (DSG) transmission, refer to 851403 The 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.

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

Fig 1: Identifying Oil Seals Sealing Lips

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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 .