General, Technical Data - Automatic Transmission 02E: Other Volkswagen Golf Mk7

GENERAL REPAIR INFORMATION

For more information on the Direct Shift Gearbox (DSG R)

For more information regarding the DSG R, refer to the Self Study Program, "The 02E Direct Shift Gearbox Design and Function" course number 851403.

TOOLS

A complete list of special tools and workshop equipment used in the repair information can be found at the beginning of each repair procedure and at the end of each repair group.

For small fasteners with a minimal tightening specification, uncertainties often exist. Use the torque wrench -V.A.G 1783- for these fasteners.

Scheme 4

Always make sure no dirt can get into an open transmission. Dirt entering an open transmission, can cause a malfunction especially with a open DSG transmission Mechatronic -J743- and/or oil pump.

1. Do not run the engine and do not tow the vehicle if the transmission cover is removed or if there is no DSG R oil inside the transmission.
2. Always clean the connection points and the surrounding areas first, and then loosen them.
3. When installing the transmission, make sure the alignment sleeves are correctly installed between the engine and transmission.
4. Place removed parts on a clean surface and cover them so that they do not get dirty. Use foil, paper or a lint free cloth.
5. Only install clean components: Only unpack replacement parts immediately prior to installation.
6. Carefully cover or seal unpacked components if repairs cannot be performed immediately.

Scheme 5

1. No matter what kind of seals they are, they must always be replaced.
2. Before installing a radial shaft seal, coat the sealing lips and the space between them with sealing grease for seal -G 052 128 A1- and the outer circumference with DSG R oil.
3. Use DSG R oil only. Other lubricants cause malfunctions.
4. The open side of the radial shaft seal faces towards the oil.
5. After installing, check the oil level and fill, if necessary. Refer to «MODIFYING THE Adapter for Oil Filling VAS 6262 A»(ref-480912-S12273275132012061900000) .

Scheme 6

Shake before opening.

The DSG R oil is obtainable as a replacement part.

The oil quality is of vital importance for transmission function.

Do not mix additives into the oil. Do not fill with a different oil.

The drained oil must not be used again.

WHEN TO CHANGE THE OIL FILTER

The oil filter does not need to be changed in every case.

DO NOT replace the filter if

1. The oil cooler or its O-rings were replaced and no coolant has gotten into the oil.
2. The selector shaft seal was replaced.
3. The flange or stub shaft seal was replaced.
4. Leaking Mechatronic covers, Direct Shift Gearbox (DSG R) clutch or oil pump were replaced.
5. The transmission input speed sensor -G182- and the clutch oil temperature sensor -G509- were replaced.

The filter MUST be replaced if

1. The 60, 000 km maintenance interval was reached.
2. Coolant has entered the oil.
3. Metal shavings were found in the oil.
4. The clutch is burned or has a mechanical fault.

Scheme 7

Up to transmission production date "September 20, 2004", transmissions with two plugs were installed.

Then, the second plug was eliminated so that oil draining and level adjusting is done using only one plug -A-.

A plastic overflow tube is located behind this plug (with a 8 mm hex socket head, tightening specification: 3 Nm). Its length determines the oil level in the transmission.

Scheme 8

1. Loosen or tighten bolts and nuts for the covers or housings diagonally.
2. The tightening specification stated apply to non-lubricated nuts and bolts.
3. Use a wire brush to clean the threads of bolts that were installed using locking fluid. Install the bolts using AMV 185 100 A1 liquid locking fluid.
4. Use a thread tap to clean all threaded holes containing self-locking bolts to remove any locking fluid residue. Otherwise the bolts could shear the next time they are removed.
5. Always replace self-locking nuts and bolts.

ELECTRICAL COMPONENTS

You have probably received a electrical shock at one time, when touching a metal item. The reason behind this is the electrostatic charge to the human body. This charge can damage the electrical components on the transmission and the selector mechanism.

Touch a grounded object before working on electric components. Do not touch connectors or open electronic components directly.

CONTROL MODULE BEHAVIOR WHEN THERE IS A MALFUNCTION, INFORMATION

The control module works with developed software. This software has the ability to execute electrical functions, monitor and control within milliseconds. Everything modern transmission electronics have going for them is located in this control module. This should also be considered during troubleshooting.

However, no electronics can do what they were not designed to do. Likewise, it is not possible to detect electronically, for example, where the transmission housing is leaking and oil is escaping. However, it is possible to detect the effects of low oil. A failure in gear monitoring would be recognized causing the control module to respond that both clutches are open (no traction).

You should know this during troubleshooting and also when working with the tester. It is possible that the cause for the malfunction might not be found during Guided Fault Finding

In addition to updating the software, much has been done to protect the transmission should there be a malfunction (safety features). And so, when necessary, malfunctions are saved and a replacement program is started.

Control Module Behavior During a Malfunction

If a component in the transmission malfunctions, the control module reacts with a replacement function. In order to protect the transmission, there are 4 different kinds of malfunctions

1. The malfunction is so minor that it is possible to continue driving with a replacement program while maintaining driving safety. The driver is not notified of this via the selector lever transmission range display -Y5-. The display shows the selector lever position normally. When can changes in driving behavior actually be detected.
2. Individual lever positions blink in the selector lever transmission range display. The driver is shown that a desired gear selection is currently not possible. An example: Reverse, lever in "R" and vehicle drives backward. If "D" is engaged in this situation, the letter "D" blinks in the selector lever transmission range display. In this case, the control module prevents 1st gear from being engaged to avoid damaging the transmission. The gear is only engaged when the vehicle is stopped.
3. The selector lever transmission range display is completely lit up and blinks. The selector lever position is indicated. An example of this: Transmission oil temperature is too high. Reasons can be, among other things: Towing a trailer with too heavy of a load, installing accessories on front of the vehicle, lack of cooling air.
4. The selector lever position cannot be recognized. The selector lever transmission range display blinks. Differences in the driving and shifting can definitely be felt. It is not possible to shift into reverse. There is a serious malfunction, a sub-transmission is switched off, transmission repair is necessary.

TRANSMISSION CODE LETTERS, READING

The transmission code letters are on the transmission in at least in two different locations.

On the transmission near the selector lever cable -two arrows-.

If these cannot be read, then transmission code letters can also be read under the transmission mount bracket.

To read the transmission code letters under the bracket directly from the transmission, the engine and transmission must be supported. The transmission mount bracket -A- must be removed. Lower the engine/transmission just enough until it is possible to slide the bracket toward the rear. If lowered further, the pendulum support could be damaged. After being assembled, the selector lever cable must be adjusted. Refer to SELECTOR LEVER CABLE, ADJUSTING .

Scheme 9

A detailed description of how to remove the bracket is not needed here. Refer to "Transmission, Removing".

Short Description

Remove the air filter housing and battery.

Install the engine support bridge 10-222 A and support the engine/transmission. Do not lift it up yet.

Remove the engine mount to engine mount bracket bolts -2- and the engine mount bracket to transmission bolts -1-.

Scheme 10

Then, lower the engine/transmission slightly using the engine support bridge 10-222 A spindles until the bracket -A- can be removed.

In most cases, 2 turns on the spindle are enough to remove the bracket -arrow-.

Scheme 11

After installing the bracket, always adjust the selector lever cable. Refer to SELECTOR LEVER CABLE, ADJUSTING .

Scheme 12

1. Filter, refer to «OIL FILTER»(ref-480912-S20835569332012061900000) For information on changing the filter, refer to «WHEN TO CHANGE THE OIL FILTER»(ref-480911-S21158236142012061900000) .
2. Inspection Plug, refer to «OIL DRAIN AND INSPECTION PLUGS»(ref-480911-S39926955252012061900000) Near the pendulum support.
3. Oil Drain Plug Refer to «DSG R OIL»(ref-480911-S25827530992012061900000) . This plug is no longer installed as of September 2004. The oil can be drained through the inspection plug.
4. Transmission Oil Cooler, refer to «TRANSMISSION OIL COOLER»(ref-480912-S03283716412012061900000)
5. DSG Transmission Mechatronic -J743-, refer to «DSG R ELECTRIC/ELECTRONIC COMPONENTS AND LOCATIONS»(ref-480912-S04217165362012061900000)
6. Transmission Input Speed Sensor -G182- and Clutch Oil Temperature Sensor -G509-, refer to «DSG R ELECTRIC/ELECTRONIC COMPONENTS AND LOCATIONS»(ref-480912-S04217165362012061900000)
7. Oil Pump, refer to «OIL PUMP»(ref-480912-S28847633842012061900000)
8. Dual Clutch Cover (End Cover)
9. Dual Clutch, refer to «DIRECT SHIFT GEARBOX OVERVIEW»(ref-480913-S01258705632012061900000)

TRANSMISSION ALLOCATION CODES

If original replacement parts are needed for a repair, always pay attention to the transmission codes.