Volkswagen Workshop Service and Repair Manuals

Removing mechatronic unit for dual clutch gearbox -J743-; gearbox is installed Special tools and workshop equipment required

t  Assembly lever -T10407- 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, the air filter housing, if present, charge air lines or coolant lines. In Polo 2010, for example, radiator fan control unit -J293- with retainer. Any retainers fitted to the bolts in the cover of the mechatronic unit must be removed. Tester moves all gear actuators »into neutral«. In this position, insert assembly lever -T10407- between clutch lever and gearbox housing. This makes it possible to remove load from plungers of mechatronic unit so that they may be removed by hand from cups of engaging levers. Mechatronic unit can be removed and inserted. When installing, make sure clutch plungers are correctly seated in cup of engaging levers. Therefore, please follow description below step by step.   Note t  The clutch is self-adjusting. Shocks can have an effect on this adjusting device. Even if the mechatronic unit has been removed, the »sudden removal« of the assembly lever -T10407- from under the engaging levers can have a negative effect on the adjusting mechanism. t  In order to remove the mechatronic unit, sufficient space must be available in front of the gearbox. In some vehicles, parts must be removed which do not have anything to do directly with the gearbox. Remove any charge air lines or coolant lines that may be present. t  Any retainers fitted to the bolts in the cover of the mechatronic unit are also removed. t  A »new« mechatronic unit is correctly filled with oil. t  Do not drain oil. A »removed« mechatronic unit is sent back with its oil in. Mechatronic unit remains filled with oil. Removing: –  Raise vehicle. All 4 supports of lifting platform must be at same height. –  Move selector lever to position »P« position. –  Remove noise insulation → Rep. gr.50. –  Drain gear oil, then reinstall drain plug → Chapter.

In some vehicles, a cover is fitted over the engaging levers. The cover prevents dirt getting in. Torque setting: 8 Nm –  Connect vehicle diagnosis, testing and information system -VAS 5051-. –  Select Guided fault finding. –  Under „7-speed dual clutch gearbox“, select Moving gear actuator into -neutral- position. –  Switch off ignition. –  Raise vehicle. –  Remove complete air filter housing → Rep. gr.24.

–  Remove battery and -battery tray- → Rep. gr.27. –  Remove starter → Electrical system; Rep. gr.27.

–  Release mechatronic unit connector by pulling and pull off connector. –  Drain gear oil, then reinstall drain plug → Chapter.

–  Pull cap off breather and close using a suitable plug to achieve an oil-tight seal.

–  Remove all retainers and brackets from front of gearbox.

–  Using a screwdriver, carefully unclip gearbox input speed sender 3 -G641- from housing in direction of arrow.

The next step is »difficult«:

Now press both engaging levers of dual clutch »away« from plungers of mechatronic unit. Otherwise, levers will jam mechatronic unit at plungers and prevent mechatronic unit from being removed.

–	Please read through this description all the way to the end first. This should help you to perform the following steps »correctly«.

Both levers must now be carefully pressed away from the plungers.

–	First take a look at -reddish-brown- engaging lever in this picture.

–	Insert assembly lever -T10407- to the right.

–	Far enough until groove lines up with housing rib.

No further.

–	Assembly lever -T10407- should make contact with gearbox housing with its entire »rear face«.

Caution Housing rib and groove of lever must be flush with one another. Do not insert tool as far as stop.

–  Apply a bit of force to tip of lever when turning. This stops lever from slipping out when turning.

Turn assembly lever -T10407- anticlockwise. In this way, engaging levers are pressed away from plungers.

Do not take out assembly lever -T10407-. It must remain inserted between clutch lever and gearbox housing for the entire process.

–	If necessary, press assembly lever -T10407- against gearbox using a screwdriver.

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.

–  Unscrew bolts of mechatronic unit for dual clutch gearbox -J743-»in diagonal sequence«. »There are 4 long and 3 short bolts.« Do not remove more than 7 bolts! –  Therefore, look carefully to check which bolts you are unscrewing. Do not unscrew any cover bolts.

The gearbox is shown here again from the side to make this situation clearer. The mechatronic unit must be removed. The cover does not have to be removed. Therefore, do not remove more than 7 bolts! –  Remove mechatronic unit. Mechatronic unit remains filled with oil.

–  Make sure no oil runs out of breather. Mechatronic unit is delivered for reconditioning with its oil in. If mechatronic unit »jams« and cannot be removed:

Sometimes, the mechatronic unit cannot be removed. In this case, the gear actuator is »caught« at the »top left« of the gearbox housing.

–	First reposition mechatronic unit on gearbox housing and secure it with one bolt.

–	Move mechatronic unit into »removal position« by hand → Chapter.

Installing mechatronic unit → Chapter.