Volkswagen Golf Service & Repair Manual: Removing and Installing Mechatronic Unit For Dual Clutch Gearbox - J743

Volkswagen Golf Service & Repair Manual - Removing and installing m... http://www.vwgolf.org/removing_and_installing_mechatronic_unit_for_...
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Volkswagen Golf Service & Repair Manual:

Removing and installing mechatronic unit for dual
clutch gearbox -J743
Volkswagen Golf Service & Repair Manual / 7- speed dual clutch gearbox 0CW / Gearbox mechanism, operation, contruction, diff / Mechatronic unit /
Removing and installing mechatronic unit for dual clutch gearbox -J743
Special tools and workshop equipment required

Vehicle diagnostic tester
Used oil collection and extraction unit -V.A.G

1782-
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Engine bung set -VAS 6122-; alternatively sealing

cap -0AM 325 120 A-
Assembly lever -T10407-
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Guide pin -T10406-
Diesel extractor -VAS 5226-

Requirement:
Gearbox is installed.
Brief description
In order to remove the mechatronic unit, sufficient
space must be available in front of the gearbox.
Depending on the vehicle, parts must be removed
which do not have anything to do directly with the
gearbox. For example: air filter housing, if
present, charge air lines or coolant lines.
Fitted retainers may also have to be removed.
Tester moves all gear actuators »into neutral
position«.
In this position, insert assembly lever -T10407-
between clutch lever and gearbox housing.
Safety note on mechatronic unit for dual clutch
gearbox -J743-
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DANGER!
Do not work on pressure accumulator. The accumulator is under pressure and is not allowed to be opened.
Caution
Danger of irreparable damage to gearbox.
Do not run engine or tow vehicle with mechatronic unit for dual clutch gearbox -J743- removed or when
there is no gear oil in the gearbox.
Note
Observe → Chapter „Repair instructions“.
The clutch is self-adjusting. Shocks can have an effect on this adjusting device. Even if the mechatronic
unit has been removed, suddenly pulling out the assembly lever -T10407- from under the engaging levers
can have a negative effect on the adjusting mechanism.
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A »new« mechatronic unit is correctly filled with oil. Do not drain or top up oil.
Recalibrate the immobiliser after installing a »new« mechatronic unit.
If a mechatronic unit is sent back, always observe the corresponding requirements.
Removing
– Raise vehicle. All 4 supports of lifting platform must be at same height.
– Move selector lever to position »P«.
Note
The vehicle diagnostic tester moves all gear actuators into “neutral” position.
In this position, insert assembly lever -T10407- between engaging lever and gearbox housing. This allows
for removing load from plungers of mechatronic unit so that they can be removed by hand from mountings
of engaging levers.
– Connect vehicle diagnostic tester and switch on ignition.
– Select the following menu options:
Guided Functions
02 - 7-speed dual clutch gearbox
Basic setting neutral
– Switch off ignition.
Vehicles with diesel engine:
Remove air filter housing → Rep. gr.23.
Continued for all vehicles:
– Remove noise insulation → Rep. gr.66.
Caution
Risk of damaging gearbox components beyond repair.
Do not under any circumstances touch the contacts in the gearbox connector by hand. Electrostatic
discharge can seriously damage the control unit and mechatronic unit.
– Touch earth connection (without gloves) in order to discharge yourself.
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Disconnect electrical connector -1- for

mechatronic unit for dual clutch gearbox
–
-J743-. To do this, pull locking mechanism
upwards -arrow-.
Unscrew nuts -2- and -3- and remove wiring
–
retainer from gearbox.
– Tie up wiring in area of gearbox cover.
Put used oil collection and extraction unit

–
-V.A.G 1782- underneath.
– Unscrew oil drain plug of gearbox.
Allow oil to drain off, then screw in oil drain
–
plug firmly again.
Caution
It is not possible to check the fill level of the
hydraulic fluid section of the mechatronic unit
for dual clutch gearbox -J743-. For installation
work, the breather of the mechatronic unit for
dual clutch gearbox -J743- must be sealed so that
no oil can escape → Anchor. If any oil escapes
from the hydraulic fluid section of the
mechatronic unit for dual clutch gearbox -J743-,
it is not possible to replenish it or check the
level!
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Pull cap -arrow- off breather connection on

mechatronic unit. Seal connection using a clean
–
plug from engine bung set -VAS 6122- so that
no oil can escape.
Note
The breather cap on the mechatronic unit is
destroyed during removal and must be renewed.
The mechatronic unit can be sealed using sealing
cap -0AM 325 120 A- as an alternative
→ Electronic Parts Catalogue (ETKA).
– If fitted, remove cover on engaging levers.

The cover prevents dirt getting in.
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Carefully pull gearbox input speed sender 3

–
-G641- out of gearbox -arrow-.
Note
The following work step serves to lift off both
engaging levers of the dual clutch from the
plungers of the mechatronic unit. If this is not
done, the engaging levers will jam the
mechatronic unit at the plungers and prevent the
mechatronic unit from being removed.
Insert assembly lever -T10407- under plunger

-2- between gearbox housing and both
–
engaging levers -1--arrow-, as shown in
illustration.
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Insert assembly lever -T10407- just enough

until groove is flush with housing rib
–
-arrows-, as shown in diagram. Do not insert
onto stop.
Note
The back of the assembly lever must rest against
the gearbox housing when doing this.
Apply a bit of force to tip of lever when

–
turning.
This stops lever from slipping out when turning.
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Turn assembly lever

-T10407- anticlockwise. In
this way, engaging levers are
pressed away from plungers.
Do not take out assembly lever -T10407-. The assembly lever remains inserted between clutch lever and
gearbox housing for the entire process.
– If necessary, press assembly lever -T10407- against gearbox using a screwdriver.
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Note
The assembly lever -T10407- must remain inserted between clutch lever and gearbox housing after
removing the mechatronics. Removing the lever could have a negative effect on the clutch adjustment.
Caution
Risk of damaging mechatronic unit for dual clutch gearbox -J743-.
Do not loosen the bolts for cover of the mechatronic unit for dual clutch gearbox -J743-.
Place the removed mechatronic unit for dual clutch gearbox -J743- down in such a way that no oil can
escape through the breather.
Oil which has been drained out cannot be filled again
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– Remove bolts -B- in diagonal sequence.

Unscrew bolts -A-, and remove mechatronic
–
unit from gearbox.
– Make sure no oil runs out of breather.
On some vehicles, a coolant hose prevents the
mechatronic unit from being removed. In this
case, reinsert mechatronic unit, and secure it
against falling down with a bolt.
Remove lower left coolant hose from radiator

–
→ Rep. gr.19.
Some additional space in front of the
mechatronic unit can be obtained by removing
the pendulum support from the gearbox. This
allows the gearbox to be »pushed back« a little
in order to remove the mechatronic unit.
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Remove bolts -1- securing pendulum support to

–
gearbox.
Remove mechatronic unit, and place it in such a
– way that no oil can escape from the breather
hole.
Caution
Risk of damaging mechatronic unit for dual
clutch gearbox -J743-.
Sometimes, the mechatronic unit cannot be
removed.
In this case, the gear actuator is caught at the top
left of the mechatronic unit.
The mechatronic unit must not be pulled out
using excess force.
In this case, the mechatronic unit should first be
brought into the installation position by hand
→ Chapter.
Note
The remaining oil must be extracted from the
gearbox before the mechatronic unit is fitted.
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All the oil remaining in the gearbox must be

–
removed using diesel extractor -VAS 5226-.
Installing
Requirement:
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The assembly lever -T10407- is inserted between

clutch lever and gearbox housing.
Note
Observe the following when installing a new
mechatronic unit:
After unpacking a new mechatronic unit, do not
discard the packaging or the red cap on the
breather pipe. These will be needed for returning
the old mechatronic unit.
A »new« mechatronic unit is correctly filled with
oil. Do not drain or top up oil.
Recalibrate the immobiliser after installing a
»new« mechatronic unit.
Before inserting mechatronic unit, check each
–
of the 4 selector forks in gearbox by hand.
Each selector fork has 3 positions:
Gear engaged
Neutral position -N-
Gear engaged
Move each of the 4 selector forks one after the
other into each position -arrows-. Slightly turn
–
one wheel to ease the movement of the selector
forks.
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N - Neutral position
R - Reverse gear
1 - First gear
2 - Second gear
3 - Third gear
4 - Fourth gear
5 - Fifth gear
6 - Sixth gear
7 - Seventh gear
– Then move all selector forks back to »centre position« (position -N-).
– Clean sealing surface where mechatronic unit will make contact later on.
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– Screw in guide bolts -T10406- by hand.

Make sure that the gear actuators are adjusted
correctly:
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Caution
Risk of damaging mechatronic unit for dual clutch gearbox -J743-.
When levering out the plungers, do not use the sensors as an anchor point.
– Move the 4 gear actuators of the mechatronic unit for dual clutch gearbox -J743- to the specified position.
Specified position: -a- = 25 mm.
– Clean sealing surface of mechatronic unit.

The seal around mechatronic unit for dual clutch
gearbox -J743- must be fully and properly inserted
in the groove.
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– Put on mechatronic unit.

Insert and tighten new bolts for mechatronic
–
unit. Specified torques: → Fig.
Caution
Risk of damaging clutches.
If the engaging levers strike the clutch
actuators of the mechatronic unit hard, these
will be placed under excess pressure and the
self-adjusting device of the clutch will become
active. Self-adjustment cannot be reversed.
Both clutch actuators must be engaged correctly
in retainers of clutch engaging levers -arrow-.
Do not damage rubber grommets of clutch
actuators when doing this.
Rubber grommets must seal properly against
mechatronic unit.
Carefully and slowly turn assembly lever

–
-T10407- in clockwise direction and remove it.
The plungers must slide slowly into the
mountings.
Pull out plungers by hand until they are
–
properly seated in mountings.
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Pull sealing plug off breather connection on

– mechatronic unit and fit new breather cap
-arrow-.
If present, install cover on engaging levers.

–
Specified torques → Chapter
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Install new bolts -1- securing pendulum support

– to gearbox, if they have been removed before
→ Rep. gr.40.
Further installation is carried out in the reverse
order of removal; note the following:
– Fill with gear oil → Chapter.
Check selector lever cable adjustment and
–
adjust it if necessary → Chapter.
– Install noise insulation → Rep. gr.66.
After installation, perform a Complete reset by
– means of Guided functions → Vehicle
diagnostic tester.
Exploded view - mechatronic unit Moving mechatronic unit for dual clutch gearbox
-J743- into removal position by hand
1 - Bolt For securing mechatronic unit for
dual clutch gearbox -J743- on gearbox housing. Note Only if you cannot set the mechatronic unit
Qty 3, M8 x 35 Always renew ... to removal position with the vehicle diagnostic
tester, you must set the unit by hand to removal
position. ...
Other materials:
Assembly overview - rear brakes

Assembly overview - rear brakes: Note Use the brake filling and bleeding equipment -VAS 5234- to draw
off brake fluid from the brake fluid reservoir. Before removing a brake caliper or disconnecting ...
Overview of fitting locations – controls in front doors

Note The illustration shows fitting locations for LHD vehicles. Fitting locations for RHD vehicles are
similar. 1 - Driver side interior locking button for central locking system -E308- Removing and installing
→&nb ...
Changing bulbs in the front bumper

Fig. 236 In the front right wheel housing liner: changing a bulb in the headlight First read and observe the
introductory information and safety warningsBefore changing the bulb in the left-hand headlight, turn the
steering wheel all the way to the right. Before changing the bulb in the righ ...
© 2016-2019 Copyright www.vwgolf.org
21 of 21 8/6/2019, 10:45 AM

Volkswagen Golf Service & Repair Manual: Removing and Installing Mechatronic Unit For Dual Clutch Gearbox - J743

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Volkswagen Golf Service & Repair Manual - Removing and installing m... http://www.vwgolf.org/removing_and_installing_mechatronic_unit_for_...

Volkswagen Golf Service & Repair Manual:

Special tools and workshop equipment required

Used oil collection and extraction unit -V.A.G

Engine bung set -VAS 6122-; alternatively sealing

Assembly lever -T10407-

Guide pin -T10406-

Diesel extractor -VAS 5226-

Disconnect electrical connector -1- for

Put used oil collection and extraction unit

Pull cap -arrow- off breather connection on

no oil can escape.

– If fitted, remove cover on engaging levers.

Carefully pull gearbox input speed sender 3

Insert assembly lever -T10407- under plunger

Insert assembly lever -T10407- just enough

Apply a bit of force to tip of lever when

Turn assembly lever

– Remove bolts -B- in diagonal sequence.

Remove lower left coolant hose from radiator

Remove bolts -1- securing pendulum support to

All the oil remaining in the gearbox must be

The assembly lever -T10407- is inserted between

– Screw in guide bolts -T10406- by hand.

– Clean sealing surface of mechatronic unit.

– Put on mechatronic unit.

Carefully and slowly turn assembly lever

Pull sealing plug off breather connection on

If present, install cover on engaging levers.

Install new bolts -1- securing pendulum support

Assembly overview - rear brakes

Overview of fitting locations – controls in front doors

Changing bulbs in the front bumper

© 2016-2019 Copyright www.vwgolf.org

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