Repair Information
Repair Information
The maximum possible care, cleanliness and proper tools are essential to ensure satisfactory and successful transmission repairs. The usual basic safety precautions also apply when carrying out vehicle repairs.
Some general repair information that applies to several procedures throughout this service information is summarized here. It applies to this repair information.
Guided fault finding, vehicle diagnosis and test instruments
• Before performing repairs on the transmission, the cause of the malfunction must be determined as accurately as possible in the operating modes "Guided Fault Finding", "Vehicle On-Board Diagnosis" and "Test Instruments".
Oil, environmental and disposal regulations
• Handle ATF, transmission oil and other oils carefully.
• Dispose of drained oil properly.
• Follow the legal environmental and disposal regulations.
• Follow the information provided on oil packaging.
Special Tools and Equipment
Transmission
• Rules for cleanliness when working on the DSG transmission. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
• Do not run engine or tow vehicle with ATF oil pan removed or without transmission fluid.
• When replacing the transmission. Refer to => [ ATF, Checking Level and Correcting ] Procedures and => [ Front Final Drive and Transfer Case, Checking Transmission Oil Level and Filling ] Front Final Drive and Transfer Case, Checking Transmission Oil Level and Filling.
• Make sure alignment bushings are properly fitted during installation.
O-rings, shaft seals, seals
• Rules for cleanliness when working on the DSG transmission. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
• O-rings, shaft seals and seals must be replaced.
• After removing gaskets and seals, always inspect the contact surfaces at housing or shaft for burrs resulting from removal, or for other signs of damage.
• Clean the housing separating surface thoroughly before assembling.
• Before installing, lightly lubricate shaft seal outer circumference and sealing lips with ATF or gear oil, depending on installation location.
• Coat O-rings with ATF before inserting to prevent crushing rings during installation.
• Only use ATF for automatic transmission components. Other lubricating substances cause functional problems in the hydraulic transmission control.
• The open side of the shaft seals point toward the fluid to be sealed in.
• After installing. Refer to => [ ATF, Checking Level and Correcting ] Procedures and => [ Front Final Drive and Transfer Case, Checking Transmission Oil Level and Filling ] Front Final Drive and Transfer Case, Checking Transmission Oil Level and Filling. Specifications.
Bolts and Nuts
• Loosen bolts in reverse order of tightening.
• Nuts and bolts which secure covers and housings should be tightened in stages according to the specified sequence and tightening method.
• Tighten and loosen bolts or nuts for securing covers and housings without tightening sequence in diagonal sequence in stages.
• Replace self-locking bolts and nuts.
• Clean threads of bolts that were applied with locking fluid using a wire brush. Then insert the bolts with liquid locking compound; Locking compound.
• Threaded holes into which self-locking bolts or bolts coated with locking fluid are screwed, must be cleaned (e.g. tap). Otherwise there is a risk that the bolts will shear the next time they are removed.
• The tightening specifications stated apply to non-oiled nuts and bolts.
Fasteners
• Do not over-stretch circlips.
• Replace damaged or stretched circlips.
• Circlips must locate properly in the groove.
Mount
• Install needle bearings with lettered side (thicker metal) towards fitting tool.
• Lubricate bearings with gear oil or ATF, depending on installation location.
• Do not interchange the outer or inner races for the same size bearings.
• Always replace the taper roller bearings on one shaft together and use new bearings from a single manufacturer.
Adjusting Shims
• Use a micrometer to measure the shims at several points. Different shim thicknesses make it possible to select the required thickness precisely; install two shims if necessary.
• Check for burrs and damage. Only install perfect shims.
Mechatronic
CAUTION!
There is a risk of destroying the transmission control module (Mechatronic) with static discharge.
• Always discharge "static electricity" before working with connectors or the mechatronic. Do this by touching a grounded object, e.g. vehicle ground, the vehicle or the hoist.
• Do not touch contacts in transmission connector with hands.