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Dis-/assembly instruction

VAG DSG6 02E Mechatronic

Brand

VAG

Model

DQ250

Product

Mechatronic

Version

1.0

Document code

P0051.03.01

Content
1.

Required Tools .................................................................................................................3

2.

Disassembly ....................................................................................................................4

3.

Assembly instruction .......................................................................................................8

4.

Basic settings with VCDS ...............................................................................................11

5.

Test drive.......................................................................................................................15

1. Required Tools

Required Tools

Measurement

Ratchet

Cap

10mm

Cap

24mm

Flat screwdriver

Hex key

8mm

Hex key

14mm

Torx head

30

Oil drip tray

Min. 10L

Torque wrench with a range of at least 5 to 35Nm.


Special VW tool to fill the gearbox with oil (VAS 6262).
Tip:

To create more room during dis-/assembly it is possible to remove


the engine mount under the engine block. When this is gone it will
be possible to pull the engine block to the rear and thus create more
room in front.

2. Disassembly
Step

Action

2.1

Turn the ignition off

2.2

See if there is a radio with radio


code, and check the radio code.

2.3

When the ignition is off,


disconnect the ground cable
from the battery.

2.4

Turn the bayonet fitting of the


Mechatronic connector counter
clockwise and pull the plug.

2.5

Tighten the bolts -2- of holder -1on the oil sump and remove the
holder from the oil sump.

2.6

Place an oil drip tray under the


transmission.

Step

Action

2.7

Unscrew the oil plug -B- (hex


14mm) and then remove the
overflow pipe (hex 8mm) behind
the drain plug. Drain the oil.

2.8

When the gearbox is empty,


mount the overflow pipe (6Nm)
and then the oil plug -B- again,
specified torque 35Nm.

Step

Action

2.9

Loosen the bolts (torx


30) of the cover on
the side of the
gearbox. Remove the
cover cap.

Step

Action

2.10

Loosen the bolts of


the oil sump in
diagonal sequence
(torx 30).

2.11

Remove the oil sump


and rubber packing.

Step

Action

2.12

Disconnect the 4-pin


connector (sensor G182 and
G502).

Step

Action

2.13

Remove the bolts from the


Mechatronic in specified
order.

Step

Action

2.14 Carefully pull the

Mechatronic away
from the gearbox
housing. While doing
so, pay close attention
to the long sensor arm
below the oil pump.
This is very vulnerable.

Step

Action

2.15 Check the

Mechatronic for
visible damage. If
damaged, please
report this when filling
out the
Remanufacture Order
Form which is sent
along with the
Mechatronic to
ACtronics.
2.16 Place the Mechatronic

in ACtronics transport
box. Again, be careful
with the long sensor
arm.

3. Assembly instruction
Step

Action

3.1

Carefully place the Mechatronic


in the gearbox housing. Pay
attention to the long sensor
arm, which must be placed into
the housing as pictured.

Step

Action

3.2

Mount the bolts of the


Mechatronic in the order
specified, specified torque 5Nm
+ 90 ( turn).

3.3

Mount the 4-pin connector


(G182 and G502).

3.4

Place the oil sump and mount


the bolts in diagonal sequence,
specified torque 10 Nm.

3.5

Place the cover cap of the oil


pump and mount the bolts in
diagonal sequence, specified
torque 8Nm.

3.6

Mount the holder on the oil


sump.

3.7

Connect the ground cable. Do


not start the engine!

Change oil filter


Step

Action

3.8

Selector lever in position P

3.9

Remove air filter

3.10

Remove battery and battery


support

Recommendation:
- A residual amount of oil will remain in
the oil filter. This will leak when
removing the oil filer.
- Before removing the oil filter, cover the
surrounding area with absorbent cloths.
3.11

Loosen filter case -arrow- about


7 rev. to begin with.

3.12

Wait approx. 10 seconds so that


the oil from the filter case can
flow back into the gearbox.

3.13

Now the filter case and oil filter


can be removed.

Step

Action

Recommendation:
Clean the oil-polluted areas on the
gearbox thoroughly.
3.14

Place the new oil filter with


collar -arrow- downwards.

3.15

Insert and tighten the filter


case (with 20Nm).

Fill gearbox with oil

Stap

Actie

3.16

Only use the specified oil to fill the gearbox (set VAS6262).

3.17

Unscrew the drain plug, and check if the overflow pipe is present.

3.18

Mount the adapter -A- steadily in the drain hole.

3.19

Fill the gearbox with the specified amount of oil.

3.20

Remove the adapter and fit the drain plug.

3.21

Start the engine, keep the brake pedal pressed in and select every gear with
the selector lever fora bout 3 seconds. Put the gear selector lever back into
position P. Do not turn the engine off.

3.22

Disassemble the drain plug again, at a gearbox temperature of 35C to


45C. For gearbox temperature, see measuring block, group 019 (VCDS).
The gearbox will run empty, until the overflow pipe, and wait until it drips.
The oil level is now up to par.

3.23

Fit the drain plug, specified torque 35Nm.

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4. Basic settings with VCDS


Conditions:

Oil temperature 30 to 100 degrees, see Measuring Blocks, group 019 .


Put the gear selector lever in position P.
Turn the ignition on.
Start the engine and let it idle for at least 1 minute.
Press the brake pedal (applies to the whole procedure).
Do not use the gas pedal.

NOTE: Make sure that the following


steps are taken in specified order,
followed by the test drive.

Step Action (Transmission tolerances calibration)

4.1 Start VCDS


4.2 Select [02 - Transmission]
4.3 Select [Basic Settings - 04]
4.4 Go to group 061 and press [Go!]

Wait until the numbers have stopped moving, and then the
gearbox will also stop making sounds. At the top of the screen
it will say ON instead of OFF. Now the basic settings for
group 061 are done (this can take up to a minute).

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Step

Action (Transmission tolerances (synchronization point))

4.5

Go to group 060 and press [Go!]


Wait until the numbers have stopped moving, and then the
gearbox will also stop making sounds. At the top of the screen
it will say ON instead of OFF. Now the basic settings for
group 060 are done (this can take up to a minute).

Step

Action (Gear adaption)

4.6

Control Module Software version < 0800 (circled in the


picture below)

4.7

Go to group 062 and press [Go!]


Activate basic settings [ON/OFF/Next]

4.8

Control Module Software Version> = 0800 : (circled in the


picture below)

4.9

Go to group 067 and press [Go!]


Activate basic settings [ON/OFF/Next]

12

Step

Action (Value reset (gear safety function))

4.10

Go to group 068 and press [Go!]

4.11

Activate basic settings [ON/OFF/Next]

4.12

Wait until the numbers have stopped moving, and then the gearbox
will also stop making sounds. At the top of the screen it will say ON
instead of OFF. Now the basic settings for group 068 are done.

Step

Action (Value reset (pressure adaptation))

4.13

Go to group 065 and press [Go!]

4.14

Activate basic settings [ON/OFF/Next]

4.15

Wait until the numbers have stopped moving, and then the gearbox
will also stop making sounds. At the top of the screen it will say ON
instead of OFF. Now the basic settings for group 065 are done.

Step

Action (Value reset (steering wheel installation tiptronic))

4.16

Go to group 063 and press [Go!]

4.17

Activate basic settings [ON/OFF/Next]

4.18

Wait until the numbers have stopped moving, and then the gearbox
will also stop making sounds. At the top of the screen it will say ON
instead of OFF. Now the basic settings for group 063 are done.

Step

Action (Value reset (ESP and cruise control installation)

4.19 Go to group 069 and press [Go!]


4.20 Activate basic settings [ON/OFF/Next]
4.21 Wait until the numbers have stopped moving, and then the gearbox

will also stop making sounds. At the top of the screen it will say ON
instead of OFF. Now the basic settings for group 069 are done.

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Step

Action (basic settings)

4.22 [Done , Go Back] Ignition off , wait 10 seconds and turn it

back on.
4.23 [Error Codes - 02] Check and delete error codes after

successful test.
4.24 [Close Controller , Go Back - 06] Finally, do the test drive.

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5. Test drive
Conditions:

Oil temperature 30 to 100 degrees, see Measuring Blocks, group 019 .


Dont use the Cruise Control.
Step Action (Test drive)
th
5.1 Drive in Tiptronic mode from standstill until 6 gear. Make sure

to drive for at least 5 minutes in 4th or 6th gear, and an


additional 5 minutes in 3rd or 5th gear. Also switch gears
between 1200 and 3500 rpm (this is necessary for the clutch
calibration).
Put the gear selector in D and hit the brakes fast, followed by a
(full throttle) acceleration (this is necessary for the oil return line
check) . Make sure that the gearbox switches gears while driving
slow, and check for leakage from the gearbox.
NOTE 1:
If the test drive cannot be performed immediately, or exactly as
described, the remaining adjustments will take place
automatically during normal driving.
NOTE 2:
For some modules [ON/OFF/Next] does not work. If an error
occurs when pressing the button, or if the status of the basic
settings do not turn on, just let the selected group finish the
procedure on its own.
It is normal that the gearbox makes noise while performing the
basic settings/adaptation. Therefore, do not terminate the basic
settings prematurely.

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