Servicing - 02E: Other Audi TT 8N facelift

TRANSMISSION

The transmission code is located on the top of the transmission, near the oil cooler. (Scheme 77) The code letters of the transmission are also given on the vehicle data stickers.

Scheme 77

The direct shift transmission 02E is also referred to as a dual-clutch transmission. The engine torque is transferred to the transmission via the dual-mass flywheel. The set-up of the transmission is the same as that of a 6-speed manual transmission. The two multi-plate "wet" clutches are regulated hydraulically and actuated alternately so that the transmission is operated like an automatic transmission, i.e. the gears are engaged automatically or manually via tiptronic. There is no clutch pedal.

SAFETY FUNCTIONS OF THE TRANSMISSION CONTROL MODULE

If one or more of the system components or sensors fails, the Transmission Control Module (TCM) -J217- will switch to a corresponding back-up mode, or emergency running program. This enables the transmission to continue operating without becoming damaged, but will impair the operation and smoothness of the gearshifts.

Faults detected by the transmission are classified in four different categories.

1. The fault is stored and a backup program enables the vehicle to drive on (in some cases with restrictions). The driver will not be made aware of the problem, as it is not critical to driving safety or to the transmission itself. The gear selection indicator in the instrument cluster will continue to show the selector lever position currently engaged in the normal way. If at all, the driver will only notice the fault if he experiences driveability problems and will then contact an Audi dealer to identify the cause.
2. Certain positions on the gear selection indicator in the instrument cluster start to flash. This is to inform the driver that this particular selector lever position is currently not available. Example: position "D" is not available when selector lever is in position "R" and vehicle is still rolling backwards. In this case, selector lever position "D" will start to flash on the gear selection indicator in the instrument cluster. The transmission control module prevents the 1st gear from being engaged in order to avoid damage to the transmission. 1st gear will be engaged once the vehicle has come to a standstill.
3. The complete gear selection indicator in the instrument cluster is lit up and flashing. The current selector lever position is indicated in the instrument cluster (e.g. "D" is highlighted). This is an indication that the transmission has been overloaded or the maximum temperature in the transmission has been exceeded (overheating), e.g. by towing a load that was too heavy.
4. If the complete gear selection indicator in the instrument cluster is lit up and flashing, this means that a serious fault in the transmission has been identified. The display in the instrument cluster no longer shows the current selector lever position. The fault is critical with regard to driving safety or to the transmission itself. It may no longer be possible to use all gears. The driver is made aware by the flashing gear selection indicator that he should immediately contact an Audi dealer.

SELECTOR MECHANISM

On an automatic transmission, information regarding the selector lever position is transmitted via the selector lever cable and the multi-function switch. The dual-clutch transmission, however, has a separate control module in the selector mechanism to transmit information on selector lever positions and gear shifts to the transmission control module via the CAN bus. This means that gear shifts are effected without a cable. Exception: In selector lever position "P" the selector lever cable is used to mechanically engage the parking lock.

GEAR OIL

The gear oil level in transmission and final drive (front) is checked and topped up together. See GEAR OIL LEVEL, CHECK & TOPPING UP .

1. Only the oil available as a replacement part may be used in the direct shift transmission 02E. Other oils cause faults and/or failure of the transmission.

The oil level in the bevel box is checked and topped up separately.

1. Only the gear oil available as a replacement part may be used for the bevel box. Other oils cause faults and/or failure of the bevel box.

REGULATIONS FOR THE DISPOSAL OF OIL

Make sure that used oil is taken to the appropriate collection center for recycling.

1. Improper disposal of used oil endangers the environment.
2. It is forbidden to add solvents, brake fluid, coolant or similar to the used oil.
3. Please observe the information shown on the packaging of the oil.

GEAR SHIFT POINT VARIATIONS FOR HILLS

An additional gear change map automatically selects gear changes for hills depending on accelerator pedal position and driving speed.

1. Gear change map for extreme uphill stretches is matched to engine output.
2. Gear change map for extreme downhill stretches is matched to the braking effect of the engine.
3. The engine braking effect can also be fully exploited via a specific gear, e.g. on hills when towing a trailer, by directly selecting a gear with the tiptronic.

NOTES ON TOWING & STARTING

It is not possible to start the engine by means of tow-starting, for instance, in the case of insufficient battery charge or if the starter is not working.

REPAIR INSTRUCTIONS

Proper tools and the maximum possible care and cleanliness are essential for successful transmission repairs. The usual basic safety precautions also naturally apply when performing vehicle repairs.

1. Do not run the engine or tow the vehicle with the oil pan removed or when there is no gear oil in the transmission.
2. When replacing the transmission the gear oil, checking and topping up must be checked and topped up, if necessary. See «CHECKING FLUID LEVEL»(ref-172698-S32597101142005030300000) . Filling quantities and specification. See «CAPACITIES»(ref-172698-S02851626732005030300000) .
3. Thoroughly clean all joints and surrounding areas before disassembling.
4. When installing the transmission, ensure that the dowel sleeves are fitted correctly.

O-RINGS, OIL SEALS, GASKETS

1. Always install new O-rings, oil seals and gaskets.
2. After removing gaskets and seals, always inspect the contact surface on the housing or shaft for burrs resulting from removal or for other signs of damage.
3. Always replace paper gaskets. Completely remove old gasket and clean sealing surfaces thoroughly.
4. Lightly lubricate the outer circumference and sealing lip of oil seals with gear oil before installing.
5. Lightly lubricate O-rings with gear oil or Vaseline before inserting to prevent them from getting crushed during assembly.
6. Do not use any other lubricants where gear oil is used. Otherwise, there is a risk of problems occurring in the transmission hydraulics.
7. The open side of the oil seals faces the side with fluid filling.
8. Observe the rules for cleanliness. See
9. After installing, check the gear oil level, adjust to correct level if necessary. See «CHECKING FLUID LEVEL»(ref-172698-S32597101142005030300000) .

LOCKING ELEMENTS

1. Do not overstretch locking rings/circlips; replace if necessary.
2. Locking rings/ circlips must be properly seated in the base of the groove.

NUTS, BOLTS

1. Loosen bolts in reverse sequence to the specified tightening sequence.
2. Nuts and bolts which secure covers and housings should be loosened and tightened in a diagonal sequence and in stages if no tightening sequence is specified.
3. Replace self-locking nuts.
4. Clean the threads of bolts which are secured by a locking compound with a wire brush. Then apply AMV 185 101 A1 when inserting.
5. The tightening torques stated apply to NON-OILED nuts and bolts.

RULES FOR CLEANLINESS

1. Thoroughly clean all joints and surrounding areas before disassembling.
2. Place removed parts on a clean surface and cover them over. Use sheeting and paper. Use lint-free cloths.
3. Carefully cover or seal open components if repairs cannot be performed immediately.
4. Only install clean components: do not remove replacement parts from packaging until just before installation.
5. Always install new O-rings, oil seals and gaskets.
6. Always replace paper gaskets. Completely remove old gasket and clean sealing surfaces thoroughly.
7. Clean the threads of bolts which are secured by a locking compound with a wire brush. Then apply AMV 185 101 A1 when inserting.

BATTERY DISCONNECT PRECAUTIONS

Before disconnecting battery, obtain anti-theft code for radio. After reconnecting battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows.

On vehicles equipped with Audi Telematics by OnStar(R), switch-off the emergency (back-up) battery for the Telematic/Telephone Control Module prior to disconnecting vehicle battery. Emergency battery is turned on and off using VAG 1551/VAG 1552 or VAS 5051/VAS 5052 scan tool in address word 75 - TELEMATICS set to function 10 - ADAPTATION CHANNEL 08.

TRANSMISSION FLUID CAPACITIES

Bevel Box

Note. The bevel box is secured to the side of the transmission and has a separate self-contained oil reservoir. (Scheme 87)

BEVEL BOX CAPACITIES

Only the gear oil available as a replacement part may be used for the direct shift transmission 02E. Other oils cause faults and/or failure of the transmission.

When changing gear oil always replace the gear oil filter, see GEAR OIL FILTER .

Only the gear oil available as a replacement part may be used for the bevel box. Other oils cause faults and/or failure of the bevel box.

Note. The bevel box is secured to the side of the transmission and has a separate self-contained oil reservoir. (Scheme 87)

Check fluid level at 20,000 mile intervals. Fluid is filled for life. No changing is required.

The gear oil in the bevel box only needs to be drained if repairs are required. It is not necessary to change the oil (lifetime filling).

Scheme 78

1. Vehicle diagnostic, testing and information system VAS 5051
2. Drip tray V.A.G 1306
3. Adapter VAS 6262
4. Safety goggles
5. Protective gloves (acid resistant)
6. An approx. 1 meter long transparent hose (commercially available) which can be attached to adapter VAS6262 and a suitable funnel (Scheme 78)

Gear Oil Precautions

1. The engine must not be started if significant oil loss has occurred (e.g. during repairs) and there is little or no oil left in the transmission.
2. If necessary, perform a pre-filling of gear oil for the direct shift transmission.
3. Only the gear oil for the direct shift transmission (available as a replacement part) may be used for the direct shift transmission 02E. Other oils cause faults and/or failure of the transmission.

Gear Oil Level, Checking

1. Transmission must not be in emergency running (backup) mode.
2. Vehicle must be level (horizontal).
3. Selector lever at position "P".
4. Engine idling.
5. Air conditioning and heating system switched off.
6. Vehicle diagnostic, testing and information system VAS 5051 connected; vehicle self-diagnosis and vehicle system "02 - Gearbox electronics" selected.
7. The gear oil temperature at the beginning of the test must not be higher than 30° C. If necessary, first allow the transmission to cool down

1. The gear oil temperature is taken from the reading on the vehicle diagnostic, testing and information system VAS 5051.
2. The gear oil level will vary according to the gear oil temperature.
3. If the gear oil level is checked when the gear oil temperature is too low, this will result in overfilling.
4. If the gear oil level is checked when the gear oil temperature is too high, this will result in underfilling.
5. Both overfilling and underfilling have a detrimental effect on the functioning of the transmission.

Reading Gear Oil Temperature

Connect information system VAS 5051 (or equivalent aftermarket scan tool) to Data Link Connector (DLC) under left side of dash.

Scheme 79

From list - 1 - select diagnostic function "08 - Read measured value block". (Scheme 80)

Scheme 80

Indicated on vehicle diagnostic, testing and information system VAS 5051.

1. Enter display group (max. input value = 255).

Use keypad - 2 - to enter "19" for "Display group number 19" and confirm by touching Q key. (Scheme 81)

Scheme 81

Reading for gear oil temperature is shown in display zone - 1 -. (Scheme 82)

Scheme 82

Checking & Correcting Gear Oil Level

Shift selector lever into "P" position, apply parking brake.

Start engine and let it idle.

Press and hold brake pedal.

With brake pressed, select all gear positions "P, R, N, D, S" one after another at idling speed, maintaining each position for at least 3 seconds.

Drive vehicle onto a four-column hoist or over an inspection pit in order for it to be absolutely horizontal.

Remove center sound insulation fasteners. (Scheme 83)

Scheme 83

Place drip tray V.A.G1306 under transmission.

Read gear oil temperature in display zone - 1 -. (Scheme 82)

When gear oil has reached a temperature of 35° C, unscrew oil inspection plug - B -. (Scheme 84)

Scheme 84

Note. The inspection plug is located next to the pendulum support. The gear oil will drain off completely if the drain plug - A - is opened.

Gear oil in overflow pipe - arrow 2 - will drain off first. (Scheme 85)

Scheme 85

Note. Even when the gear oil level is low a small amount of oil will first drain out of the overflow pipe, as it fills up during operation.

Check that overflow pipe is secured to transmission with a torque of 3 Nm. Tighten if necessary

Note. If the overflow pipe is not correctly secured, the oil level cannot be correctly read.

Drain excess transmission oil.

The gear oil level is correct when a small amount of gear oil still drains out when the oil temperature is between 35° C and 45° C (level rises due to warming of oil).

In this case, the gear oil does not need to be topped-up; oil level is OK.

Note. Every 30 seconds a small surge of oil will come out of the oil level pipe regardless of the oil level (cause: intermittent cooling oil supply to the clutch). The surge is not to be considered a criteria for the correct oil level and should therefore be disregarded. Gear oil that has drained off must not be refilled or reused. Dispose of the gear oil properly.

Replace seal - arrow - for gear oil inspection plug. (Scheme 86)

Scheme 86

Screw in inspection plug - B -. Tightening torque: 45 Nm.

The gear oil check is now completed.

End function "08 - Read measured value block" by touching key.

Press "06 - End output".

Switch off ignition and unplug diagnostic connector.

If no gear oil drains out when the oil temperature is between 35° C and 45° C, top up gear oil. See GEAR OIL LEVEL, TOPPING UP .

GEAR OIL LEVEL, TOPPING UP

Note. If no gear oil drains out of the overflow pipe - arrow 2 - when the engine is running and the oil temperature is between 35° C and 45° C, the gear oil must be topped up. (Scheme 85)

1. All conditions and procedures for checking the gear oil must be adhered to.

Screw adapter VAS6262 into opening of inspection plug - B - finger tight. (Scheme 84)

Attach hose with funnel to adapter and hold funnel as high as possible above transmission.

Initially add only a small amount of gear oil for transmission using funnel.

Check Gear Oil Level (Check As Often As Necessary)

Remove hose from adapter VAS6262 and plug hose using a clean plug.

Gear oil in overflow pipe - arrow 2 - will drain off first. (Scheme 85)

Drain excess transmission oil.

The gear oil level is correct when a small amount of gear oil still drains out when the oil temperature is between 35° C and 45° C (level rises due to warming of oil).

In this case, the gear oil does not need to be topped-up; oil level is OK.

Note. Every 30 seconds a small surge of oil will come out of the oil level pipe regardless of the oil level (cause: intermittent cooling oil supply to the clutch). The surge is not to be considered a criteria for the correct oil level and should therefore be disregarded. Gear oil that has drained off must not be refilled or reused. Dispose of the gear oil properly.

If no more gear oil drains out of the inspection plug hole, continue to top up and check the oil until the oil level is OK.

Unscrew adapter VAS6262 from transmission.

Replace seal - arrow - for gear oil inspection plug. (Scheme 86)

Screw in inspection plug - B -. Tightening torque: 45 Nm.

The gear oil check is now completed.

End function "08 - Read measured value block" by touching key.

Press "06 - End output".

Switch off ignition and unplug diagnostic connector.

Requirements

1. Vehicle must be level (horizontal).
2. Selector lever at position "P".
3. Engine not running.
4. The gear oil filter must always be replaced when changing gear oil.

1. Observe all notes and test requirements for "Gear oil level, checking". See «GEAR OIL LEVEL, CHECKING»(ref-172698-S32597101142005030300000) .
2. Note regulations for the disposal of oil. See «REGULATIONS FOR THE DISPOSAL OF OIL»(ref-172698-S15340426642005030300000) .

Filling With Gear Oil

Screw correct overflow pipe into opening for inspection plug (tightening torque: 3 Nm).

Screw adapter VAS6262 into opening of inspection plug - B - finger tight.

Attach hose with funnel to adapter and hold funnel as high as possible above transmission.

Fill with 6 liters of gear oil for direct shift transmissions using a funnel.

Unscrew adapter VAS6262 from transmission.

Drain off excess transmission oil.

Screw in inspection plug - B -.

Shift selector lever into "P" position, apply parking brake.

Press and hold brake pedal.

Start engine and let it idle.

With brake pressed, select all gear positions "P, R, N, D, S" one after another at idling speed, maintaining each position for at least 3 seconds.

Check and top up gear oil level. See GEAR OIL LEVEL, CHECKING .

BEVEL BOX GEAR OIL, CHECKING & TOPPING UP

Note. The bevel box is secured to the side of the transmission and has a separate self-contained oil reservoir. (Scheme 87)

Notes

1. Rules for cleanliness when working on the transmission. See «RULES FOR CLEANLINESS»(ref-172698-S22028667852005030300000) .
2. General repair instructions. See «REPAIR INSTRUCTIONS»(ref-172698-S18764883212005030300000) .
3. Observe notes on direct shift transmission 02E, disposing of oil. See «REGULATIONS FOR THE DISPOSAL OF OIL»(ref-172698-S15340426642005030300000) .

Checking Gear Oil In Bevel Box - B

The bevel box is secured to the side of the transmission and has a separate self-contained oil reservoir. (Scheme 87)

Scheme 87

1. Vehicle must be level (horizontal).
2. Engine not running.

Checking & Topping Up

Drive vehicle onto a four-column hoist or over an inspection pit in order for it to be absolutely horizontal.

Remove center sound insulation fasteners. (Scheme 83)

Place drip tray V.A.G1306 under transmission.

Remove gear oil inspection plug - B -. (Plug - B - must be replaced after removing). (Scheme 88)

Scheme 88

Oil level is correct when gear oil is up to lower edge of filler hole in bevel box.

If necessary, top up gear oil via hole for inspection plug - B -.

Screw in new plug - B -. Tighten to 15 Nm.

Work Sequence

Remove plug - B -. (Plug - B - must be replaced). (Scheme 88)

Fill up gear oil for bevel box to lower edge of filler hole.

Screw in plug - B -.

Start engine, engage a gear and allow transmission to turn for approx. 2 minutes.

Switch off engine and remove plug - B -.

Fill gear oil for bevel box up to bottom edge of filler hole.

Screw in new plug - B -. Tighten to 15 Nm.

Scheme 89

1. Hose clamps, up to 25 mm diameter 3094
2. Torque wrench V.A.G1331 (Scheme 89)

Scheme 90

Removing

Disconnect ground strap on battery with ignition switched off.

Loosen clamp and disconnect intake hose and connector - 1 - from mass air flow sensor. (Scheme 91) If installed, disconnect hose from air cleaner housing.

Scheme 91

Remove bolts - 4 - and - 6 - and remove complete air cleaner housing. (Scheme 91)

Clamp off hoses for gear oil cooler with hose clamps up to 25 mm diameter 3094 and disconnect from gear oil cooler. (Scheme 92)

Scheme 92

Remove 3 bolts - A -. (Bolts must be replaced). (Scheme 93)

Scheme 93

Remove gear oil cooler - B - together with O-rings - C - from transmission.

Installing

Perform installation in reverse sequence of removal. Note the following

Replace O-rings on gear oil cooler.

Tighten NEW bolts - A - to 20 Nm, plus 90° further (90° equals one quarter of a turn). (Scheme 93)

Follow steps required after connecting battery. See BATTERY DISCONNECT PRECAUTIONS .

Check coolant level in cooling system. See COOLING SYSTEM SPECIFICATIONS & DRIVE BELT ROUTING article.

Check and top up gear oil level. See GEAR OIL LEVEL, CHECKING .

1. Engine not running.

Disconnect ground strap on battery with ignition switched off.

Loosen clamp and disconnect intake hose and connector from mass air flow sensor. (Scheme 91)

If installed, disconnect hose from air cleaner housing. Remove bolts 4 and 6 and remove complete air cleaner housing. (Scheme 91)

Unscrew filter housing - B -. (Scheme 92)

Note. Tip the filter housing several times before removing to drain gear oil from the housing.

Slowly remove gear oil filter upward.

Note. An O-ring is located in the intake neck of the filter. Make sure that it does not remain in the transmission; remove it if necessary.

Perform installation in reverse sequence of removal. Note the following

Replace gear oil filter.

Lubricate O-ring in intake neck of new filter with gear oil before installing into transmission.

Lubricate O-ring on filter housing with gear oil before screwing onto transmission.

Tighten filter housing - B - to 20 Nm. (Scheme 92)

Follow steps required after connecting battery.

Check and top up gear oil level. See GEAR OIL LEVEL, CHECKING .

1. Engine not running.

1. Rules for cleanliness when working on the transmission. See «RULES FOR CLEANLINESS»(ref-172698-S22028667852005030300000) .
2. General repair instructions. See «REPAIR INSTRUCTIONS»(ref-172698-S18764883212005030300000) .
3. Observe notes on direct shift transmission 02E. See «NOTES ON THE DIRECT SHIFT TRANSMISSION 02E»(ref-172698-S34811879002005030300000) .
4. Lightly lubricate O-rings and seals with gear oil. Other types of lubricant will cause the transmission hydraulics to malfunction.

Disconnect ground strap on battery with ignition switched off.

Remove center sound insulation tray fasteners. (Scheme 83)

Vehicles With Lines For Power Steering Attached To Cross Piece

Disconnect lines for power steering from cross piece - arrows -. (Scheme 94)

Scheme 94

Vehicles With Lines For Power Steering Attached To Transmission

Disconnect lines for power steering from transmission and remove speed nut from transmission.

Remove cross piece - arrows -. (Scheme 95)

Scheme 95

Unscrew nut - 1 - and press bracket - A - upward. (Scheme 96) Bracket - A - is secured to front of transmission oil pan. (Scheme 96)

Scheme 96

All Vehicles

Place drip tray V.A.G1306 under transmission.

Remove drain plug - A - and allow gear oil to drain off. See GEAR OIL, CHANGING OR FILLING AFTER REPAIRS .

If installed, remove protective plate at bottom of transmission - arrows -. (Scheme 97)

Scheme 97

Turn bayonet catch - 1 - of 20-pin connector to release and separate it from transmission. (Scheme 98)

Scheme 98

Touch a vehicle ground by hand (without gloves) to discharge any static electricity.

Loosen 5 bolts on oil pan - arrows - in diagonal sequence. (Bolts must be replaced). (Scheme 99)

Scheme 99

Note. There is still a small amount of gear oil in the transmission, as not all oil can drain.

Remove oil pan together with oil pan gasket.

Installation is performed in reverse sequence. Note the following

Replace O-rings - B - on 20-pin connector for Direct Shift Gearbox (DSG) Mechatronic -J743-. (Scheme 100)

Scheme 100

Lubricate O-rings lightly with gear oil.

Clean gasket and sealing surfaces and remove any oil residue. Make sure the oil pan gasket is installed correctly.

Note. When installing the oil pan, be careful not to trap any wiring.

Tighten 5 new bolts for oil pan - arrows - in a diagonal sequence in stages to 89 INCH lbs. (10 N.m). (Scheme 99)

Renew the seal for drain plug.

Install drain plug - A - . Tighten to 45 Nm.

Fill with gear oil. See GEAR OIL, CHANGING OR FILLING AFTER REPAIRS .

Note. The seal for inspection plug must be replaced after checking gear oil.

Connect battery.

Follow steps required after connecting battery.

1. Read rules for cleanliness when working on the automatic transmission. See «RULES FOR CLEANLINESS»(ref-172698-S22028667852005030300000) .
2. General repair instructions. See «REPAIR INSTRUCTIONS»(ref-172698-S18764883212005030300000) .
3. Lightly lubricate O-rings and seals with gear oil. Other types of lubricant will cause the transmission hydraulics to malfunction.

Disconnect ground strap on battery with ignition switched off.

Remove oil pan. See OIL PAN, REMOVING & INSTALLING .

Touch a vehicle ground by hand (without gloves) to discharge any static electricity.

Carefully release connector - A - (e.g. using a small screwdriver) and remove from mechatronic. (Scheme 100)

Note. Do not pull on the connector wire - A - . If the wire becomes damaged, the Sensor for transmission RPM / Transmission fluid temperature sensor -G182-/-G93- will have to be replaced. See SENSOR FOR TRANSMISSION RPM / TRANSMISSION FLUID TEMPERATURE SENSOR -G182- / -G93- , REMOVING & INSTALLING .

Release wire for sensors from retainers - arrows - on Direct Shift Gearbox (DSG) Mechatronic -J743-. (Scheme 100) Remove bolts in reverse order from - 10 - to - 1 -. (Bolts must be replaced).

Remove Direct Shift Gearbox (DSG) Mechatronic - C - from transmission in a forward direction and keep it straight.

Note. The long sender on the reverse side of the Direct Shift Gearbox (DSG) Mechatronic -J743- must not become damaged.

Installation is performed in reverse sequence. Note the following

Attach Direct Shift Gearbox (DSG) Mechatronic -J743- - C - without using excessive force. (Scheme 100)

Note. When installing the Direct Shift Gearbox (DSG) Mechatronic -J743- , the wire for connector - A - must not become trapped or pinched. If the wire is damaged, the Sensor for transmission RPM / Transmission fluid temperature sensor -G182- / -G93- will have to be replaced.

The long sender on the reverse side of the Direct Shift Gearbox (DSG) Mechatronic -J743- must not become damaged.

Tighten bolts 1 to 10 finger tight. (Scheme 100)

Final tighten bolts 1 to 10, in sequence, to 5 N.m, plus 90° further (90° equals one quarter of a turn). (Scheme 100)

Secure wire to retainers - arrows -. Plug in connector - A -. (Scheme 100)

Clean gasket and sealing surfaces and remove any oil residue.

Replace O-rings - B - on 20-pin connector for Direct Shift Gearbox (DSG) Mechatronic -J743-.

Lubricate O-rings - B - lightly with gear oil.

Install oil pan.

Connect battery.

Follow steps required after connecting battery. See BATTERY DISCONNECT PRECAUTIONS .

Fill with gear oil. See GEAR OIL, CHANGING OR FILLING AFTER REPAIRS .

1. Engine not running.

1. Read rules for cleanliness when working on the automatic transmission. See «RULES FOR CLEANLINESS»(ref-172698-S22028667852005030300000) .
2. General repair instructions. See «REPAIR INSTRUCTIONS»(ref-172698-S18764883212005030300000) .
3. Lightly lubricate O-rings and seals with gear oil. Other types of lubricant will cause the transmission hydraulics to malfunction.

Disconnect ground strap on battery with ignition switched off.

Remove oil pan. See OIL PAN, REMOVING & INSTALLING .

Remove Direct Shift Gearbox (DSG) Mechatronic -J743-. See DIRECT SHIFT GEARBOX (DSG) MECHATRONIC -J743- , REMOVING & INSTALLING .

Unscrew bolt - B -. (Scheme 101)

Remove sensors - A - from transmission together with wire.

Scheme 101

Installation is performed in reverse sequence. Note the following points.

Lubricate sensors - A - with gear oil and insert into opening on side of transmission. (Scheme 101)

Install mechatronic. See DIRECT SHIFT GEARBOX (DSG) MECHATRONIC -J743- , REMOVING & INSTALLING .

Install oil pan. See OIL PAN, REMOVING & INSTALLING .

Connect battery. Follow steps required after connecting battery. See BATTERY DISCONNECT PRECAUTIONS .

Fill with gear oil. See GEAR OIL, CHANGING OR FILLING AFTER REPAIRS .

Perform basic setting using vehicle diagnostic, testing and information system VAS 5051.

Scheme 102

It is possible to replace the oil seals without removing the transmission.

1. Read rules for cleanliness when working on the automatic transmission. See «RULES FOR CLEANLINESS»(ref-172698-S22028667852005030300000) .
2. General repair instructions. See «REPAIR INSTRUCTIONS»(ref-172698-S18764883212005030300000) .

Remove left axle shaft. See AXLE SHAFTS - FWD & AWD article.

Place drip tray V.A.G1306 under transmission.

Remove countersunk bolt for flange shaft; use a drift to prevent turning. (Bolt must be replaced.)

Pull out flange shaft and spring.

Pry out oil seal with assembly lever.

Perform installation in reverse sequence of removal. Note the following

Drive in new oil seal onto stop using thrust piece 3305. (Scheme 104) Take care to keep seal straight when installing.

Scheme 103

Fill space between sealing lip and dust lip half-full with grease G52 128 A1.

Push flange shaft against spring pressure and secure using new bolt.

Install left axle shaft.

Checking gear oil level and changing gear oil. See GEAR OIL LEVEL, CHECKING .

It is possible to change the oil seals without removing the transmission.

1. Read rules for cleanliness when working on the automatic transmission. See «RULES FOR CLEANLINESS»(ref-172698-S22028667852005030300000) .
2. General repair instructions. See «REPAIR INSTRUCTIONS»(ref-172698-S18764883212005030300000) .

Remove right axle shaft. See AXLE SHAFTS - FWD & AWD article.

Unbolt heat shield for axle shaft (right side) from bevel box. (Scheme 105)

Scheme 104

Place drip tray V.A.G1306 under transmission.

Remove bolt for flange shaft (right side) - arrow 1 - using hex key T10107. (Bolt must be replaced.) (Scheme 106)

Scheme 105

Remove flange shaft using puller T10037. (Scheme 107)

Scheme 106

Pry out flange shaft oil seal using assembly lever.

Perform installation in reverse sequence of removal. Note the following

Drive in new oil seal as far as stop using thrust piece T10049. see scheme 33

Scheme 107

Fill space between sealing lip and dust lip half-full with grease G52 128 A1.

Carefully drive in flange shaft (while turning).

Secure flange shaft using new countersunk bolt.

Install right axle shaft.

Checking oil level in bevel box. See GEAR OIL LEVEL, CHECKING .