Removing and installing mechatronic unit for dual clutch gearbox J743 — VW

Removing and installing
mechatronic unit for dual clutch gearbox
J743
Special tools and workshop equipment required
Guide pin
T10406
Assembly lever
T10407
Used oil collection and extraction unit
VAS 6622A
Vehicle diagnostic tester
For allocation of sealing plugs from
repair kit
5C0 998 152
, refer to
Electronic Parts Catalogue
.
For allocation of
protective cap
0AM 325 120 A
, refer to
Electronic parts catalogue
.
Removing
DANGER!
Before work on the high-voltage system is started, a high-voltage technician must de-energise the high-voltage system
Electrical system
Rep. gr.
93
General warning instructions for work on high-voltage system; De-energising high-voltage system
.
The types of work for which the high-voltage system has to be de-energised are indicated in the list entitled
“Work on high-voltage system”
Electrical system
Rep. gr.
93
General warning instructions for work on high-voltage system
.
Caution
Danger of irreparable damage to gearbox.
Observe the safety precautions when working on the
mechatronic unit for dual clutch gearbox
J743
Chapter
.
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.
Risk of soiling.
Thoroughly clean all joints and surrounding areas before dismantling.
In the procedure below, the hydraulic system of the
mechatronic unit for dual clutch gearbox
J743
will be opened. Any soiling will cause the system to fail.
Note
The clutch is self-adjusting. Shocks can have an effect on this adjusting device. Even if the
mechatronic unit for dual clutch gearbox
J743
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.
After a new
mechatronic unit for dual clutch gearbox
J743
has been removed from its packaging or after it has been installed, do not dispose of the packaging or the breather pipe protective cap. These parts will be needed for returning the old
mechatronic unit for dual clutch gearbox
J743
.
A new
mechatronic unit for dual clutch gearbox
J743
is correctly filled with oil. Do not drain oil.
Move selector lever to position
»P«
.
Connect
Vehicle diagnostic tester
, and switch on ignition.
Select
Guided functions
.
Under
“7-speed dual clutch gearbox”
, select
Moving gear actuator into -neutral- position
.
Switch off ignition.
Remove engine/gearbox
Rep. gr.
10
Removing and installing engine; Removing engine
.
Loosen union nut
1
.
Pull out clip
2
.
Remove hydraulic line
3
.
Immediately seal connections
1 and 2
of hydraulic line with new sealing plugs
3 and 4
from
repair kit
5C0 998 152
.
Also connections
1 and 2
should be sealed immediately with new sealing plugs
3 and 4
from
repair kit
5C0 998 152
.
Note
Always make sure to use new sealing plugs.
It is not permissible to reuse the sealing plugs.
Pull off breather cap
1
. Breather
2
remains attached to breather connection
3
.
Remove breather
2
to prevent leakage of hydraulic fluid.
The breather will be damaged during removal and must be renewed.
Seal breather connection
1
with sealing plug or
protective cap
0AM 325 120 A
2
so that no oil can escape.
Caution
Risk of damaging gearbox components beyond repair.
Do not under any circumstances touch the contacts in the gearbox connector by hand. Otherwise, electrostatic discharge can seriously damage the control unit and thereby the
mechatronic unit for dual clutch gearbox
J743
.
Touch earth connection (without gloves) in order to discharge yourself.
Disconnect electrical connector
1
.
Open clip
2
.
Lay wiring harness to side.
Put
used oil collection and extraction unit
VAS 6622A
underneath.
Unscrew oil drain plug
1
.
Drain oil.
Afterwards, screw oil drain plug back in and tighten it.
Using a screwdriver, carefully unclip clip
2
from housing in direction of
arrow
.
Remove
gearbox input speed sender 3
G641
1
from housing.
Note
In the following work step, both engaging levers of the dual clutch will be lifted off the plungers. If this is not done, the engaging levers will jam the
mechatronic unit for dual clutch gearbox
J743
at the plungers, thus preventing the mechatronic unit from being removed.
Insert
assembly lever
T10407
under plungers
2
between gear housing and both engaging levers
1
arrow
.
Insert
assembly lever
T10407
between plunger
2
and engaging lever
1
just far enough for the groove of the lever to be flush with the housing rib
arrows
.
Note
Do not insert the
assembly lever
T10407
onto stop.
The back of the
assembly lever
T10407
must be against the gear housing when doing this.
Turn
assembly lever
T10407
90° in direction of
arrow A
(anti-clockwise).
Lift engaging lever off plungers
1
in direction of
arrow B
.
While turning, push
assembly lever
T10407
in direction of
arrow
against gearbox housing with a screwdriver.
Note
The
assembly lever
T10407
remains inserted between the engaging levers and the gear housing during removal and installation of the
mechatronic unit for dual clutch gearbox
J743
.
If necessary, press the
assembly lever
T10407
against the gearbox housing.
Caution
Risk of damaging
mechatronic unit for dual clutch gearbox
J743
.
Sometimes, the
mechatronic unit for dual clutch gearbox
J743
cannot be removed.
In this case, the gear actuator is caught at the top left of the mechatronic unit.
The
mechatronic unit for dual clutch gearbox
J743
must not be pulled out using excess force.
Rather, the
mechatronic unit for dual clutch gearbox
J743
should first be brought into the installation position by hand
Chapter
.
Do not under any circumstances touch the contacts in the gearbox connector by hand. Otherwise, electrostatic discharge may seriously damage the control unit and thereby the
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.
Do not remove the valve block from the
mechatronic unit for dual clutch gearbox
J743
.
Unscrew bolts
1
.
Remove
mechatronic unit for dual clutch gearbox
J743
2
together with valve block
3
from gearbox.
Installing
Install in reverse order of removal, observing the following:
The breather connection of the
mechatronic unit for dual clutch gearbox
J743
is sealed with a sealing plug or the
sealing cap
0AM 325 120 A
so that no oil can escape.
Connection on valve block is sealed with suitable sealing plug
arrow
from
repair kit
5C0 998 152
.
Note
A new
mechatronic unit for dual clutch gearbox
J743
is correctly filled with oil.
The
mechatronic unit for dual clutch gearbox
J743
is supplied with the
protective cap
0AM 325 120 A
fitted to seal it off.
Before installing the
mechatronic unit for dual clutch gearbox
J743
, ensure that all selector forks are in
»centre position«
.
The
»centre position«
is illustrated as position
N
(neutral) in the illustration below.
In this position no gear is engaged. That is, the neutral position is set.
First, check each of the 4 selector forks 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
.
Then move all selector forks back to
»centre position«
(position
N
).
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
Clean sealing surface where
mechatronic unit for dual clutch gearbox
J743
will make contact later on.
Screw in
guide bolts
T10406
by hand.
Adjusting gear actuator:
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 at the back of the
mechatronic unit for dual clutch gearbox
J743
to the specified position.
Specified position:
a
= 25 mm.
Clean sealing surface.
The seal around
mechatronic unit for dual clutch gearbox
J743
must be fully and properly inserted in the groove.
The
assembly lever
T10407
is inserted between engaging lever and gearbox housing.
Dowel sleeves
1
and
2
for centring
mechatronic unit for dual clutch gearbox
J743
on gearbox housing must both be installed.
Fit
mechatronic unit for dual clutch gearbox
J743
2
together with valve block
3
. When doing so, ensure that gear actuators unit are not being pushed out of their positions.
Screw in bolts
1
hand-tight.
Remove
guide pin
T10406
.
Tighten bolts.
Caution
Risk of damaging clutches.
If the engaging levers strike the clutch actuators of the
mechatronic unit for dual clutch gearbox
J743
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.
Do not damage rubber grommets of clutch actuators when doing this.
Rubber grommets must seal properly against
mechatronic unit for dual clutch gearbox
J743
.
Carefully and slowly turn
assembly lever
T10407
in clockwise direction and remove it.
Plungers
1
must slide slowly into mountings
2
.
Pull out plungers by hand until they are properly seated in mountings.
Install
gearbox input speed sender 3
G641
1
in direction of
arrow
.
Clip
2
must not be damaged.
Sender lug must be fully and firmly in contact with gearbox housing.
If sender is loose or clip is broken, renew
mechatronic unit for dual clutch gearbox
J743
.
Connect and lock connector of
mechatronic unit for dual clutch gearbox
J743
.
Renew O-ring
1
on hydraulic line
2
.
Note
Only install O-rings as per
Electronic Parts Catalogue
.
Do not remove the sealing plugs until just before installing.
It is not permissible to reuse the sealing plugs.
Install hydraulic line.
Remove
protective cap
2
from breather connection
1
.
If a large quantity of hydraulic fluid (more than 20 ml) has escaped, 30 ml of hydraulic fluid must be replenished through breather connection
1
. Use a disposable syringe
2
for this purpose.
For allocation of disposable syringe from
repair kit
5C0 998 152
and of hydraulic fluid, refer to
Electronic Parts Catalogue
.
Caution
Risk of damaging
mechatronic unit for dual clutch gearbox
J743
.
Only new bottles may be used!
Observe the expiry date of the hydraulic fluid!
Always use new disposable syringes from
repair kit
5C0 998 152
. It is not permissible to reuse disposable syringes.
Fit new breather cap
1
with breather
2
onto breather connection
3
.
Note
If the
mechatronic unit for dual clutch gearbox
J743
is removed, fit sealing plugs onto the old
mechatronic unit for dual clutch gearbox
J743
so that no oil can escape when it is sent for reconditioning.
Apply
spray for cavity sealing
D 329 215 M1
in transition area between gearbox housing and
mechatronic unit for dual clutch gearbox
J743
.
Install engine
Rep. gr.
10
Removing and installing engine; Installing engine
.
Fill with gear oil
Chapter
.
Check selector lever cable adjustment and adjust it if necessary
Chapter
.
Re-energise high-voltage system and carry out documentation
Electrical system, hybrid vehicles
Rep. gr.
93
Re-energising high-voltage system
.
After the high-voltage system has been re-energised, bleed hydraulic clutch mechanism of disengagement clutch
Vehicle diagnostic tester
.
Initiate basic adjustment
Vehicle diagnostic tester
.
Specified torques
Chapter
“
Assembly overview - mechatronic unit
”