Power transmissionRepair instructions
| Proper tools and the maximum possible care and cleanliness are essential for satisfactory gearbox repairs. Naturally, the customary basic safety rules must be observed during repair work. |
| General instructions for certain repair work that appear repeatedly in the Repair Manual are summarised below. They apply for this individual Workshop Manual. |
| Guided fault location, vehicle self-diagnosis and measurement module |
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| Before servicing the gearbox, the exact cause of the failure must be determined using the functions „Guided Fault Finding“, „Vehicle Self-diagnosis“ and „Test Instruments“ → Vehicle diagnostic tester. |
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| If the oil sump has been removed or if gear oil is needed, do not start the engine or tow the vehicle. |
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| After replacing the gearbox, the oil level in the bevelled gear must be checked → Chapter and toped up if necessary. Filling amounts and oil type specifications → Chapter. |
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| Thoroughly clean unions and adjacent areas before removing. |
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| When assembling check that fitting sleeves are correctly positioned. |
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| The screw is no longer fitted from September 2004. The oil can be drained via the inspection screw. |
| 5 - | mechatronic system for automatic DSG gearbox -J743- |
| 6 - | Gearbox input speed sender -G182- and clutch temperature sender -G509- |
| 8 - | Cover (end cover) for multi-clutch |
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| Always renew seals, O-rings and gaskets. |
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| After removing gaskets, check that the contact surfaces of the casing and shaft do not show feathering or damage caused by the removal process. |
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| Always replace paper gaskets, completely disposing of the used gasket and thoroughly cleaning the contact surfaces. |
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| Lightly lubricate the outer circumference and sealing lip of oil seals with gear oil before installing. |
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| Coat the O-rings with gear oil or Vaseline before fitting to avoid crushing during assembly. |
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| Never use other lubricants in the gear oil area. Otherwise there is a danger of operation faults being caused to the hydraulic gear mechanism. |
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| The open side of the flanges must point towards the liquid to be sealed. |
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| After installing, check gear oil level, rectify as necessary → Chapter. |
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| Do not over expand the securing rings; replace them if necessary. |
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| Retaining rings must locate properly in grooves. |
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| The bolts are removed in reverse order to the tightening sequence. |
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| The bolts or nuts to be used to secure covers and casings must be released and tightened diagonally in stages when no tightening order is specified. |
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| Renew self-locking nut. |
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| The threads of those bolts fitted using a fixing agent must be cleaned using a wire brush. Then apply locking fluid -AMV 185 101 A1- to bolt threads before installing. |
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| The specified tightening torques are for non-lubricated nuts and bolts. |
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| You are bound to have received an electric shock at some time on touching metal objects, caused by the electrostatic charge of the human body. This charge can disturb the function of electrical components of the gearbox and of the selector mechanism. |
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| Before working on electrical components, electrostatically discharge yourself (touch something that is earthed). Do not touch connectors or electronic components directly. |
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01 Transmission
The same page in:
Leon Mk2.
