Note: Follow instructions for automatic gearbox DSG - 0CW-. The clutch automatically adjusts the working clearance. Vibrations can adversely affect the clutch adjuster. Even if the mechatronic is removed, pulling out the pry bar -T10407- under the selector levers can have a negative effect on the adjustment device. Ensure sufficient distance to the gearbox to remove the mechatronics. On some vehicles, it is necessary to dismantle components that are not directly related to the mechatronics, for example. bracket on the screws of the mechatronics cover. When disconnecting and connecting the battery cable to ground, additional work must be performed.
The mechatronic remains filled with oil
Set control lever to position "R". Immediately before removing the mechatronics, carry out the basic setting "neutral position" KP. Turn on the ignition. Set the mode -Guided functions-, then select -02 7-speed DSG gearbox- and then -Basic idle setting-. Switch off the ignition. Disconnect the battery cable to ground with the ignition off. Remove air filter. Remove battery and battery bracket.
Carefully! Risk of damage to gearbox components. It is strictly forbidden to touch the contacts of the gearbox connector with your hands. A discharge of static electricity can damage the control unit and with it the mechatronic unit.
Touch your hand (without gloves) to ground to remove the electrostatic charge. Unlock the mechatronics plug by pulling in the -direction of the arrow- and disconnect the plug.
Remove the vent cap and plug it with a suitable plug to prevent oil from escaping.
Note: If the mechatronic breather is damaged during removal, it must be replaced. Plug the vent hole with a clean plug from the engine plug set -MS 6122- or with the cap -OAM 325120 A-.
Remove the lower soundproofing casing of the engine. Disconnect charge air hose from lower left charge air cooler and charge air pipe. Disconnect connector -1- for radiator fan. Unclip -arrow B- and remove fan shroud.
Note: The fan shroud can accommodate two fans.
Remove the electrical wires from the front mechatronics holder and tie them up. Detach the holder from the mechatronics cover. Place an oil collecting pan under the gearbox. Remove the oil drain plug - see arrow - on the KP.
Let the oil drain. Install the oil drain screw.
Note: After removing the mechatronic unit, drain the remaining oil in the gearbox using a bleeder for the diesel engine, e.g. -VAS5226-.
Remove, if equipped, the dirt protection cover above the dual clutch levers.
Remove the electrical wires from the front lower mechatronics holder and tie them up. Disconnect all holders from the gearbox.
Using a screwdriver, carefully unlock the gearbox input speed sender -G182-M in -direction of arrow- from housing.
Note: The next work step is to remove both double clutch release levers from the tappets. Otherwise, the levers will sit on the mechatronic pushers and cannot be removed.
Insert pry bar -T10407- under tappets -2- between gearbox housing and both release levers -1- -arrow- as shown.
Push in pry bar -T10407- only until the groove and recess in the gearbox housing are in the same plane -arrows- as shown in the illustration. Do not insert all the way.
Instruction. The grooves on the body and the groove on the lever must be at the same level. Do not insert pry bar -T10407- as far as it will go. The reverse side of the mount must be in contact with the gearbox housing.
When turning, do not apply much force to the end of the lever. Thus, the mount will not fall out when turning.
Turn the pry bar -T10407- in -direction of arrow- to the left and remove the selector lever from the tappet.
Instruction. Do not remove pry bar -T10407-. The pry bar remains between the dual clutch levers and the gearbox housing during the entire assembly process. If the pry bar is removed, the automatic dual clutch adjustment device may be damaged.
If necessary, press pry bar -T10407- against gearbox with a screwdriver and press both double clutch levers out of mechatronic unit.
Note: Do not damage the rubber bushings of the dual clutch adjuster. Risk of damage Mechatronics for DSG gearbox -J743-. Do not loosen screws for mechatronics cover for dual clutch gearbox -J743-. Lay down the removed mechatronic unit for the DSG gearbox -J743- so that no oil flows out through the vent holes in the mechatronic unit. If oil leaks out, it is not possible to top up the oil level and the mechatronic will have to be replaced!
Remove long screws -B- (4 pieces, M8 x 90) in cross order. Remove remaining screws -A- (3 pieces, M8 x 35) in cross order.
Note: Do not remove more than 7 screws! "These are 4 long and 3 short screws". Do not loosen the mechatronics cover screws for double-clutch gearboxes. The mechatronic unit for the dual-clutch gearbox -J743- may only be touched or touched after the electrostatic charge has been removed via a grounded object, eg the main contact mass. Never touch the plug-in contacts in the gearbox connector with your hands, so that a static discharge does not damage the control unit and mechatronics.
Touch your hand (without gloves) to ground to remove the electrostatic charge. Take out the mechatronic.
Carefully! Risk of damage to mechatronics KHDSG -J743-. It may happen that the mechatronics cannot be removed. In this case, the gear selector clamps the mechatronic in the upper left side. The mechatronic cannot be pulled out with additional force. In this case, you must first bring the mechatronics to the manual removal position, "Filmed" mechatronic returns filled with oil (plug the vent hole with a suitable plug).
Install the mechatronics with the gearbox installed.
Mechatronic for dual clutch gearbox -J743- "removal position"
It may happen that the mechatronics cannot be removed, in which case "clamped" actuating mechanism "top left" on the gearbox housing - see arrow-.
Only in the case when "removal position" cannot be set using the vehicle tester -VAS/ODIS-, the mechatronic unit must be brought into "removal position" manually, "sandwiched" the actuator can now be pressed by hand in "removal position". To do this, remove the cover of the gearbox lock when parking.
Carefully! If dropped, the mechatronics can be damaged! After being brought into "removal position" manually the mechatronic is not fixed and can fall out of the gearbox. Until this happens, secure the mechatronic to the gearbox against falling out with at least one screw.
Fully insert the mechatronic into the gearbox and secure with one screw. Set control lever to position "R", Remove the cover -1- of the parking lock mechanism.
Note: Before the next work step, the mechatronic unit must be secured against falling out of the gearbox with at least one screw.
Press the selector fork through the hole to the side -in the direction of the arrow-.
Thus "pinched" the actuator is released and the mechatronic can be removed. Remove the mechatronic unit. Clean the sealing surfaces on the gearbox and on the cover of the gearbox lock when parking.
Note: After completing work on the mechatronics and after installing it, fill the gearbox with oil through the hole in the parking lock. Lubricate sealing ring in cover with sealing compound -G 052128 A1-. Replace the shift lever mounting screws.
Install the parking lock cover and shift lever.