Volkswagen Golf Service & Repair Manual: Removing and installing mechatronic unit for dual clutch gearbox -J743
| Special tools and workshop equipment
required |
| Vehicle diagnostic tester |
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| Used oil collection and extraction unit -V.A.G 1782- |
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| Engine bung set -VAS 6122-; alternatively sealing cap -0AM
325 120 A- |
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| Diesel extractor -VAS 5226- |
| 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: air filter housing, if
present, charge air lines or coolant lines. |
| Fitted retainers may also have to be removed. |
| Tester moves all gear actuators »into
neutral position«. |
| In this position, insert assembly lever -T10407- between
clutch lever and gearbox housing. |
| Safety note on mechatronic unit for dual clutch gearbox
-J743- |
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DANGER!
| Do not work on pressure accumulator. The accumulator
is under pressure and is not allowed to be opened. |
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Caution
| Danger of irreparable damage to gearbox. |
| 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. |
|
 Note
| Observe
→ Chapter „Repair instructions“. |
| The clutch is self-adjusting. Shocks can have an effect on
this adjusting device. Even if the mechatronic unit has been
removed, suddenly pulling out the assembly lever -T10407- from
under the engaging levers can have a negative effect on the
adjusting mechanism. |
| A »new« mechatronic unit is
correctly filled with oil. Do not drain or top up oil. |
| Recalibrate the immobiliser after installing a
»new« mechatronic unit. |
| If a mechatronic unit is sent back, always observe the
corresponding requirements. |
| – |
Raise vehicle. All 4 supports of lifting platform must be at
same height. |
| – |
Move selector lever to position »P«. |
Note
| The vehicle diagnostic tester moves all gear actuators into
“neutral” position. |
| In this position, insert assembly lever -T10407- between
engaging lever and gearbox housing. This allows for removing
load from plungers of mechatronic unit so that they can be
removed by hand from mountings of engaging levers. |
| – |
Connect vehicle diagnostic tester and switch on ignition. |
| – |
Select the following menu options: |
| 02 - 7-speed dual clutch gearbox |
| Vehicles with diesel engine: |
| Remove air filter housing
→ Rep. gr.23. |
| Continued for all vehicles: |
| – |
Remove noise insulation
→ Rep. gr.66. |
Caution
| Risk of damaging gearbox components beyond repair. |
| Do not under any circumstances touch the contacts in
the gearbox connector by hand. Electrostatic discharge
can seriously damage the control unit and mechatronic
unit. |
|
| – |
Touch earth connection (without gloves) in order to
discharge yourself. |
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|
| – |
Disconnect electrical connector -1-
for mechatronic unit for dual clutch gearbox -J743-. To do this,
pull locking mechanism upwards -arrow-. |
| – |
Unscrew nuts -2- and
-3- and remove wiring retainer from
gearbox. |
| – |
Tie up wiring in area of gearbox cover. |
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| – |
Put used oil collection and extraction unit -V.A.G 1782-
underneath. |
| – |
Unscrew oil drain plug of gearbox. |
| – |
Allow oil to drain off, then screw in oil drain plug firmly
again. |
Caution
| It is not possible to check the fill level of the
hydraulic fluid section of the mechatronic unit for dual
clutch gearbox -J743-. For installation work, the
breather of the mechatronic unit for dual clutch gearbox
-J743- must be sealed so that no oil can escape
→ Anchor. If any oil escapes from the
hydraulic fluid section of the mechatronic unit for dual
clutch gearbox -J743-, it is not possible to replenish
it or check the level! |
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| – |
Pull cap -arrow- off breather
connection on mechatronic unit. Seal connection using a clean
plug from engine bung set -VAS 6122- so that no oil can escape. |
Note
| The breather cap on the mechatronic unit is destroyed during
removal and must be renewed. |
| The mechatronic unit can be sealed using sealing cap -0AM
325 120 A- as an alternative
→ Electronic Parts Catalogue (ETKA). |
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| – |
If fitted, remove cover on engaging levers. |
| The cover prevents dirt getting in. |
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| – |
Carefully pull gearbox input speed sender 3 -G641- out of
gearbox -arrow-. |
Note
| The following work step serves to lift off both engaging
levers of the dual clutch from the plungers of the mechatronic
unit. If this is not done, the engaging levers will jam the
mechatronic unit at the plungers and prevent the mechatronic
unit from being removed. |
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| – |
Insert assembly lever -T10407- under plunger
-2- between gearbox housing and
both engaging levers -1--arrow-, as
shown in illustration. |
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| – |
Insert assembly lever -T10407- just enough until groove is
flush with housing rib -arrows-, as
shown in diagram. Do not insert onto stop. |
Note
| The back of the assembly lever must rest against the gearbox
housing when doing this. |
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|
| – |
Apply a bit of force to tip of lever when turning. |
| This stops lever from slipping out when turning. |
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| Turn assembly lever -T10407- anticlockwise. In this way,
engaging levers are pressed away from plungers. |
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| Do not take out assembly lever -T10407-. The assembly lever remains
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. |
Caution
| Risk of damaging 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. |
| Oil which has been drained out cannot be filled
again |
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|
| – |
Remove bolts -B- in diagonal
sequence. |
| – |
Unscrew bolts -A-, and remove
mechatronic unit from gearbox. |
| – |
Make sure no oil runs out of breather. |
| On some vehicles, a coolant hose prevents the mechatronic
unit from being removed. In this case, reinsert mechatronic
unit, and secure it against falling down with a bolt. |
|
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|
| – |
Remove lower left coolant hose from radiator
→ Rep. gr.19. |
| Some additional space in front of the mechatronic unit can
be obtained by removing the pendulum support from the gearbox.
This allows the gearbox to be »pushed back«
a little in order to remove the mechatronic unit. |
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| – |
All the oil remaining in the gearbox must be removed using
diesel extractor -VAS 5226-. |
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| The assembly lever -T10407- is inserted between clutch lever
and gearbox housing. |
Note
| Observe the following when installing a new mechatronic
unit:
|
| After unpacking a new mechatronic unit, do not discard the
packaging or the red cap on the breather pipe. These will be
needed for returning the old mechatronic unit. |
| A »new« mechatronic unit is
correctly filled with oil. Do not drain or top up oil. |
| Recalibrate the immobiliser after installing a
»new« mechatronic unit. |
| – |
Before inserting mechatronic unit, check each of the 4
selector forks in gearbox by hand. |
| Each selector fork has 3 positions: |
| – |
Move each of the 4 selector forks one after the other into
each position -arrows-. Slightly
turn one wheel to ease the movement of the selector forks. |
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| – |
Then move all selector forks back to
»centre position« (position -N-). |
| – |
Clean sealing surface where mechatronic unit will make
contact later on. |
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| – |
Screw in guide bolts -T10406- by hand. |
| Make sure that the gear actuators are adjusted correctly: |
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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 of the mechatronic unit for dual clutch
gearbox -J743- to the specified position. |
| Specified position: -a- = 25 mm. |
| – |
Clean sealing surface of mechatronic unit. |
| The seal around mechatronic unit for dual clutch gearbox
-J743- must be fully and properly inserted in the groove. |
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| – |
Put on mechatronic unit. |
| – |
Insert and tighten new bolts for mechatronic unit. Specified
torques:
→ Fig. |
Caution
| Risk of damaging clutches. |
| If the engaging levers strike the clutch actuators
of the mechatronic unit 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 -arrow-. |
| Do not damage rubber grommets of clutch actuators when doing
this. |
| Rubber grommets must seal properly against mechatronic unit. |
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| – |
Carefully and slowly turn assembly lever -T10407- in
clockwise direction and remove it. |
| The plungers must slide slowly into the mountings. |
| – |
Pull out plungers by hand until they are properly seated in
mountings. |
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| – |
Pull sealing plug off breather connection on mechatronic
unit and fit new breather cap -arrow-. |
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| – |
If present, install cover on engaging levers. Specified
torques
→ Chapter |
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| – |
Install new bolts -1- securing
pendulum support to gearbox, if they have been removed before
→ Rep. gr.40. |
| Further installation is carried out in the reverse order of
removal; note the following: |
| – |
Fill with gear oil
→ Chapter. |
| – |
Check selector lever cable adjustment and adjust it if
necessary
→ Chapter. |
| – |
Install noise insulation
→ Rep. gr.66. |
| – |
After installation, perform a Complete
reset by means of Guided functions
→ Vehicle diagnostic tester. |
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1 -
Bolt
For securing mechatronic unit for dual clutch gearbox -J743- on
gearbox housing.
Qty 3, M8 x 35
Always renew ...
Note
Only if you cannot set the mechatronic unit to removal position with
the vehicle diagnostic tester, you must set the unit by hand to removal
position.
...
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1 -
Front cover
For electronics box in engine compartment
2 -
Nut
Specified torque: 9 Nm
3 -
Nut
Specified torque: 9 Nm
4 -
Wire/line
...
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Exploded view - mechatronic unit
Moving mechatronic unit for dual clutch gearbox -J743- into removal position
by hand