Always make sure that no dirt gets into the gearbox when the gearbox is »opened«. Penetrated dirt, especially for »exposed« mechatronics for double clutch gearbox -J743- or oil pump, can lead to the failure of the gearbox. |
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| If the covers are unscrewed from the gearbox or the gearbox is without oil, do not let the engine run and do not tow the vehicle. |
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| Thoroughly clean the connection points and their surroundings and then release. |
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| When installing the gearbox, ensure the dowel sleeves are correctly located between the engine and gearbox. |
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| Place removed parts on a clean surface and cover, in order to avoid contamination. Do not use fluffy cloths! |
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| Only install clean parts: Take out original parts from their wrapping immediately before installing. |
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| Carefully cover or close opened components if the repair is not completed immediately. |
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| If the gearbox is replaced, the oil level must be checked → Chapter. |
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| After removing gaskets, examine the contact surface in the housing or on shafts for burrs or damage, and correct if necessary. |
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| Before a radial shaft seal is installed, coat the sealing lips and the space in-between with sealing grease -G 052 128 A1- and the outer circumference with DSG oil. |
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| The open side of the sealing rings is turned towards the oil. |
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| Always replace O-rings, gasket rings and gaskets. |
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| Before inserting the O-rings coat with DSG oil to prevent the rings being damaged during installation. |
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| Only use DSG oil in the oil area. Other types of lubricant will cause the gearbox hydraulic control system to malfunction. |
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| After installing, check oil level → Chapter. |
The oil quality influences in a decisive way the function of the gearbox. |
Tasks of the oil - the oil does not only »lubricate« the gearbox. |
For your information: oil, which on the one hand transports minor abrasion particles from the differential gear to both filters, also ensures on the other hand that the grease film on the tooth flanks of the differential gear is not damaged and at the same time, by means of exerting pressure, it enables the operating switches of the gears to carry out their function. In addition, it seals the pistons and helps the synchronizer rings when shifting gears, it collects and transports heat energy, minimises noise - the tasks of the oil are very different. In order to maintain this performance, the oil as well as the oil filter of the gearbox must be changed during maintenance (instructions, when the gearbox oil filter must be replaced and when not → Anchor). |
Caution Be careful when handling oil. Dispose of drained oil appropriately. |
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| Shake oil bottle before opening. |
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| Do not mix any additives in the oil, also do not fill in other oil. |
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| Drained oil must not be refilled. |
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| The oil level in the gearbox and in the final drive must be checked and topped up jointly (vehicles with front-wheel drive) → Chapter. |
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| The oil level in the gearbox and in the final drive must be checked and topped up jointly (vehicles with four-wheel drive) → Chapter. |
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| The oil level in the angle gearbox (vehicles with four-wheel-drive) is checked and topped up separately → Chapter. |
| The filter must be replaced, if: |
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| the extended service interval was achieved: |
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| Coolant has got into the oil. |
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| Metallic swarfs were found in the oil. |
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| the clutch is blown or mechanically damaged. |
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| the gearbox oil cooler was replaced and no coolant has got into the oil. |
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| the gasket ring of the gearshift shaft was replaced. |
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| the gasket ring for flange or rigid shaft was replaced. |
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| the leaky cover of the mechatronics, the clutch or the oil pump was replaced. |
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| the gearbox input r.p.m. sender -G182- and the temperature sender for clutch -G509- was replaced. |
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