Skoda Workshop Service and Repair Manuals

Removing mechatronics for double clutch gearbox -J743-; gearbox installed (Fabia II, Roomster) Special tools and workshop equipment required t  Assembly lever -T10407- t  Vehicle Diagnosis, Measurement and Information System -VAS- t  Catch pan for workshop crane -VAS 6208-   Note t  Observe safety instruction for the mechatronics for double clutch gearbox -J743- → Chapter. t  Observe instructions for automatic gearbox DSG - 0AM → Chapter. t  General repair information → Chapter. t  The clutch is self-adjusting. Vibrations can have a negative effect on the adjusting device. Also when the mechatronics is removed, the »sudden removal« of the special tool below the engaging levers can have a negative effect on the adjusting device. t  The mechatronics is allocated according to the gearbox code letters → Electronic Catalogue of Original Parts. t  Ensure adequate clearance in front of the gearbox in order to remove the mechatronics. Components, which are not directly connected with the gearbox, must be removed on some vehicles. The existing brackets, if applicable, must be removed at the screws of the cover for mechatronics. t  After the battery earth strap is disconnected and connected, carry out additional operations → Electrical System; Rep. gr.27. The mechatronics remains filled with oil –  Shift selector lever into position »P«. –  Connect vehicle diagnosis, measurement and information system -VAS-. –  Select Targeted functions. –  Under „7-speed double clutch gearbox“, select bring gear actuator into neutral position. –  Switch off ignition. –  Disconnect the battery-earth strap with the ignition off → Electrical System; Rep. gr.27. –  Remove air filter → Engine; Rep. gr.24. –  Remove battery and battery tray → Electrical System; Rep. gr.27. –  Removing starter → Electrical System; Rep. gr.27.   Caution Under no circumstances must the plug contacts in the plug of the gearbox be touched with the hands, because the control unit can be destroyed through static discharge as well as the mechatronics. –  Grab with the hand (without gloves) at the mass, in order to discharge yourself electrostatically.

–  Unlock the cap for the plug of the mechatronics by pulling in -direction of arrow- and disconnect the plug. –  Unclip the electrical cables from the top bracket at the front of the gearbox.

–  Remove the cap -arrow- from the ventilation and close with a suitable screw plug so that no oil can flow out.   WARNING Hot steam may escape after the compensation bottle is opened. Cover the cap with a cloth and open carefully. –  When the engine is warm the cooling system is under pressure. Slowly open the cap of the compensation bottle, in order to first reduce pressure before pulling off the coolant hoses. –  Raise vehicle. –  Remove the sound dampening system → Body Work; Rep. gr.50. –  Position the catch pan under the gearbox.

–  Release oil drain plug -arrow- at the gearbox.

–  Drain off oil. –  Install oil drain plug.

Vehicles with radiator fan control unit -J293- –  Unscrew the nuts -3- from the left frame side rail and tie up the radiator fan control unit -J293--4-.   Note Do not disconnect the plugs -1- and -2-. Continued for all vehicles

–  Unplug connector -arrow-.

–  Release the fan shroud on the catch hook e.g. using a screwdriver and remove → Engine; Rep. gr.19. –  Place a catch pan for workshop crane -VAS 6208- under the radiator.

–  Remove the bottom coolant hose from the radiator -arrow- and drain the coolant → Engine; Rep. gr.19. –  Remove the electrical lines from the bottom holder at the front of the mechatronics and tie up.

–  Remove all the brackets from the gearbox.

–  Carefully unlock the gearbox input r.p.m. sender 3 -G641- with a screwdriver and pull it out of the housing in -direction of arrow-.

–  Slacken the long screws -B- (4 pieces, M8 x 90) of the mechatronics for double clutch gearbox -J743-»crosswise« and release them.

–  Slacken the remaining screws -A- (3 pieces, M8 x 35) »crosswise« and release them.   Note t  Do not remove more than 7 screws! »There are 4 long and 3 short screws«. t  Do not slacken the cover screws of the mechatronics.

Now both engaging levers of the clutch control must be pressed off the tappets of the mechatronics. Otherwise the engaging levers of the mechatronics clamp at the tappets and the mechatronics cannot be removed.

–  Insert the assembly lever -T10407- between the engaging lever for the clutch control and the gearbox housing -direction of arrow-.

The assembly lever -T10407- should rest with the complete surface of the »reverse side« against the gearbox housing and the nut should form one level with the recess of the housing -arrow-.   Note Do not insert the assembly lever -T10407- up to the stop.

–  Turn the assembly lever -T10407- to the left in -direction of arrow- and thus press the engaging lever away from the tappets -arrows-.   Note

t  Exert a little force on the tip of the assembly lever -T10407- when turning it. t  This prevents that the assembly lever -T10407- slips out when turning it. t  Do not remove the assembly lever -T10407-. It remains inserted between the engaging levers and the gearbox housing during the complete assembly.

If necessary, press the assembly lever -T10407- against the gearbox using a screwdriver. –  Grab with the hand (without gloves) at the mass, in order to discharge yourself electrostatically.   Caution t  Only then touch or remove the mechatronics for double clutch gearbox -J743-, after you have discharged yourself electrostatically at an earthed object beforehand, e.g. skin contact with mass. t  Under no circumstances must the plug contacts in the plug of the gearbox be touched with the hands, because the control unit can be destroyed through static discharge as well as the mechatronics. –  Remove mechatronics.   Note

t  The mechatronics for double clutch gearbox -J743- remains filled with oil. t  Make sure no oil runs out of the ventilation. t  The mechatronics for double clutch gearbox -J743- is filled with recycled oil.

If the mechatronics for double clutch gearbox -J743-»hooks« and cannot be removed: It is possible that the mechatronics cannot be removed. In this case, the gear actuator »jams« at the »top left« on the gearbox housing. In this case, the mechatronics should not be removed with increased force. –  First reposition the mechatronics on the gearbox housing and secure it with a screw. –  In this case, the mechatronics must be put into the »removal position« by hand → Chapter. Install mechatronics on installed gearbox → Chapter.