MECHATRONIC, Removing And Installing: Removing

Always make sure that no dirt or contaminants enter an >>open<< transmission.

Any dirt that enters can cause transmission failure, especially if the DSG Transmission Mechatronic -J743- and/or the transmission fluid pump are >>open<<.

The Mechatronic can get stuck on the alignment pins when the transmission is very warm. Let the transmission cool down.

-- Move the selector lever to "P".

-- Disconnect the battery ground cable. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Remove the noise insulation. Refer to OVERVIEW - NOISE INSULATION .

-- If equipped, remove the connecting hose between the charge air cooler and the charge air pipe -1-. Refer to OVERVIEW - CHARGE AIR SYSTEM .

Fig 1: Identifying Hose And Clamps

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NOTE:

It is possible that parts, which have nothing to do with the Mechatronic unit, will have to be removed. It depends on the vehicle equipment. Make sure there is enough room around the Mechatronic unit.

Depending on the vehicle, the parts could be:
Fan mount -arrow-

Fig 2: Fan Shroud
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
Additional lines for the A/C systems
Charge or cold air pipes

CAUTION:

There is a risk of damaging the DSG Transmission Mechatronic -J743- with static electricity.

Do not touch contacts in DSG Transmission Mechatronic -J743- connector with hands.

-- To discharge any static electricity, touch the vehicle ground with hand (without wearing a glove). Refer to Electrical Components .

-- Turn the Mechatronic connector -1- >>counter-clockwise<< and then disconnect it.

Fig 3: Identifying Starter And Bayonet Catch

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NOTE:

The connector is located on the transmission near the starter -A-.

-- Remove the wires and the bracket from the transmission fluid pan -arrows- (two M6 nuts).

Fig 4: Identifying Nuts And Bracket

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-- Route the wires near the transmission fluid pan upward and tie them secure.

-- Place the : SMN372500 under the transmission near the transmission fluid pan.

CAUTION:

Fluid will leak out of the transmission fluid pan when removing the bolts. Risk of injury due to hot transmission fluid.

-- Loosen and remove the transmission fluid pan bolts -arrows- in a diagonal sequence. Hold the transmission fluid pan in place while doing so.

Fig 5: Exploded View Of Transmission Oil Pan

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-- Allow the fluid to drain and then remove the transmission fluid pan with the seal.

Approximately three liters of transmission fluid will drain out.

NOTE:

Always replace the transmission fluid pump cover, the bolts for the transmission fluid pump cover as well as the seal and bolts for the transmission fluid pan.

-- Remove the bolts -arrows- and the transmission pump cover -A-.

Fig 6: Identifying Cap For Transmission Oil Pump And Fasteners

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-- Remove the bolts -2 and 3- for the pendulum support from the transmission.

Fig 7: Identifying Pendulum Support & Bolts

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The transmission can now be >>pressed down<< slightly to remove the Mechatronic.

-- Touch a grounded object again before touching the Mechatronic.

-- Release the connector -1- of the Transmission Input Speed Sensor -G182- and Clutch Oil Temperature Sensor -G509- using the : T10465 .

Fig 8: Identifying Connector -1- And Release Tool - T10465-

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NOTE:

If the : T10465 is not available, the connector can also be released by carefully using two screwdrivers as follows:

Press only on the locking mechanism with the screwdriver -1-. Do not use a screwdriver as a lever.

Fig 9: Identifying Connector For Transmission Input Speed (RPM) Sensor G 182 With Clutch Oil Temperature Sensor G509

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Loosen the connector -2- using a screwdriver.

Be very careful. The connector locking mechanisms can break. If this happens, the sensor must be replaced.

Do not pull on the wire.

-- Disconnect the connector.

-- First remove line from the lower clamp -arrow I-.

Fig 10: Locating Wire Clamps

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-- Then remove from the second clamp -arrow II- and move it to the side. Do not kink line.

-- Loosen and remove the bolts -1 through 10- in the specified sequence.

Fig 11: Direct Shift Gearbox Mounting Bolts Removal Sequence

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-- Carefully pull the Mechatronic out of the transmission housing until the sensor arm -B- on rear side is no longer located in transmission housing.

Fig 12: Identifying Alignment Of Pin In Transmission Housing And Sensor Arm In Guide

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When handling the Mechatronic, be particularly aware of the >>long<< sensor arm -B-.

-- Carefully move the DSG Transmission Mechatronic -J743- downward.

Store Mechatronic Properly

Fig 13: Caution Handling Mechatronic

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CAUTION:

Never lift the Mechatronic by the >>sensor arm<< and never let it rest on the arm.