General Repair Information

Using the Repair Manual 

Refer to the "7-Speed DSG^® Transmission 0CK" repair manual for all special procedures with the transmission installed, depending on the model. The servicing repair manual either does not describe them or describes them only partially. Both repair manuals are needed for a successful repair.

The highest level of care and cleanliness along with tools that function properly are required to ensure a proper and successful transmission repair. Of course the general safety precautions also apply when carrying out repair work.

Some general repair information that applies to several procedures throughout this manual is summarized here. They apply to this repair manual.

Oil, Environmental and Disposal Regulations 

• Handle ATF, transmission fluid and other oils carefully.
• Dispose of drained fluid properly.
• Follow the legal, environmental, and disposal regulations.
• Follow the instructions listed on the fluid packaging.

Special Tools 

Refer to Workshop Equipment and Special Tools for a complete list of special tools used in the repair manual.

Transmission 

• Follow all the guidelines for clean working conditions. Refer to RULES FOR CLEANLINESS WHEN WORKING ON DSG .
• Do not run the engine or tow the vehicle when the transmission is open or when there is no transmission fluid.
• If installing parts that can be used again, clean and check them and replace if necessary.
• During installation, make sure the alignment sleeves are fitted correctly.

O-rings, Shaft Seals, Seals 

• Always replace the O-rings, shaft seals and seals.
• After removing the seals, examine the contact surface on the 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 the installation location.
• Depending on the component location, coat the O-rings lightly with ATF or transmission fluid to insert them. This prevents them from being crushed when being installed.
• Use only ATF in the ATF area. Other lubricants cause malfunctions in the hydraulic transmission control.
• The open side on the shaft seals faces the fluid to be sealed off.
• After installing check the ATF level or the transmission fluid level with the transmission installed and correct. Refer to "7-Speed Dual Clutch Transmission 0CJ, 0CK, 0CL" ATF CIRCUIT or for transmission fluid level checking and correcting, refer to TRANSMISSION FLUID . Specification. Refer to the Parts information.

Bolts and Nuts 

• Loosen the bolts opposite the tightening sequence.
• Nuts and bolts which secure covers and housings should be tightened in steps according to the specified tightening sequence or method.
• Bolts or nuts for securing covers and housings should be loosened and tightened diagonally in stages if no tightening sequence is specified.
• Always replace self-locking bolts and nuts.
• If nothing else is specified: Use a wire brush to clean the threads of bolts that were screwed in with locking compound. Use locking fluid when installing the bolts. Refer to the Parts information.
• If self-locking bolts were installed or if regular bolts were installed with locking fluid, then the threaded holes must be cleaned, for example with a thread tap. Otherwise there is the risk that the bolts could break off the next time they are removed.
• The tightening specifications given apply to unoiled bolts and nuts.

Circlips, Snap Rings 

• Do not stretch the circlips.
• Replace damaged or stretched circlips.
• The circlips must rest at the bottom of the groove.

Bearings 

• Install needle bearings with the lettered side (thicker metal) facing the fitting tool.
• Coat and install the bearings with gear oil or with ATF, depending on the installation location.
• Do not interchange the outer or inner races of bearings of the same size.
• Always replace the tapered roller bearings on one shaft together and use new bearings from a single manufacturer.

Shims 

• Measure the shims at several locations with a micrometer. Different shim thicknesses make it possible to select the required thickness precisely; install two shims if necessary.
• Check for burrs or damage. Only install flawless shims.

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