MK5 Golf GTI

All Things Mk5 => Modifications & Technical Area => Technical Workshop => Topic started by: omeydz on April 11, 2015, 11:28:09 pm

Title: DSG Mechatronics hydraulic fluid refilling
Post by: omeydz on April 11, 2015, 11:28:09 pm
So Iv bought a brand new 7speed (DQ200/0AM) gearbox from dealers that they had knocking around for my DSG conversion.

However idiots stored it upside down so dsg oil and hydraulic fluid have drained out of the breather caps.

I can refill dsg oil easy but VW say you cannot refill or completely empty mechatronics unit. Some people online say its possible but cant find any how to's.

Presuming if the mechatronics has drained completely and i totally invert it so its "completely empty" I can refill 1l of hydraulic fluid in through the breather and replace the cap.

Iv fired some messaged to people who repair DSGs but wondering if anyone here can offer any help?

Many thanks  :smiley:
Title: Re: DSG Mechatronics hydraulic fluid refilling
Post by: Golf_GT_TDI on April 12, 2015, 12:27:16 am
Hmmm not sure.. 1.1l of oil is mentioned as capacity but filling of oil is not covered in VW's workshop manual for the 0AM, if you don't have them I can Email the SSP and Manual pdf's
Title: Re: DSG Mechatronics hydraulic fluid refilling
Post by: omeydz on April 12, 2015, 11:30:13 am
Iv got Elsawin manuals thanks.

It doesnt detail draining mechatronics as its not part of the remit of vw techs. They are only trained to swap them over for a new one if there is a problem. Says that in the self study VW manuals and Elsawin.

Just a question of how to drain it completely. Whether inverting it and letting gravity do its thing? If I bargain about 0.1ish litres will remain inside, I buy a full litre and feed it through the breather hole. Any excess will make its way out through the breather?

Im still being very cautious about this as I know I can screw it up. Won't attempt anything until I have some solid info on how to do it.
Title: Re: DSG Mechatronics hydraulic fluid refilling
Post by: Golf_GT_TDI on April 14, 2015, 10:01:46 pm
Yeah that sounds like the way to go about it, but yes would be good to have some solid info on the procedure. If you find anything more and/or end up giving it a go let us know how you get on  :happy2:
Title: Re: DSG Mechatronics hydraulic fluid refilling
Post by: omeydz on April 15, 2015, 11:16:47 am
Was on the phone ringing around and transpires that theres a 5mm bolt underneath the mechatronics to drain remaining fluid. I noticed it but wanted to be sure its right one!!

But for refilling I have to remove the breather cap and replace with blocking cap and refill the mechatronics from the bottom and the gearbox upside down.

Breather valves and seals dont allow you to fill or drain from the top.

Will give this a go in a few days and report back once Iv got the parts and oil from VW.  :happy2:

Good this the gearbox isnt in the car or it'd be a major faff!
Title: Re: DSG Mechatronics hydraulic fluid refilling
Post by: Golf_GT_TDI on April 15, 2015, 12:34:30 pm
Tidy, sounds like you're good to go
Title: Re: DSG Mechatronics hydraulic fluid refilling
Post by: omeydz on April 15, 2015, 01:58:25 pm
Finger x'd!
Title: Re: DSG Mechatronics hydraulic fluid refilling
Post by: mamg15 on August 02, 2015, 12:11:27 am
for curiosity, what type of hydraulic fluid need the mechatronic, i heard that if the oil have impurities can cause a short in the unit.
Title: Re: DSG Mechatronics hydraulic fluid refilling
Post by: omeydz on August 02, 2015, 11:42:49 am
Green one. I forgot latest part number but is same stuff for hydraulic power steering.

Its wrong gearbox oil not mechatronic fluid which caused shorting out. Its on google.
Title: Re: DSG Mechatronics hydraulic fluid refilling
Post by: gdaniel on January 05, 2016, 09:37:20 pm
Hey, I got leaking oil from the mechatronic unit, we would like to repair the sealing and refill it. We found how to do it, and what type of oil needed but what about the correct amount of fluid?

Could you made it?
Title: Re: DSG Mechatronics hydraulic fluid refilling
Post by: omeydz on January 06, 2016, 10:27:08 am
1L of Green genuine VW hydraulic fluid for 0AM gearbox (also used in the earlier power steering e.g. golf mk4 and hydraulic systems)
Title: Re: DSG Mechatronics hydraulic fluid refilling
Post by: gdaniel on January 06, 2016, 04:22:22 pm
So we have to drain the whole unit, repair the sealings and fill up exactly with 1 L - G 004 000 fluid.

Thanks for the help, I hope we can fix it like this, because the +1400$ replace cost is too much.
Title: Re: DSG Mechatronics hydraulic fluid refilling
Post by: omeydz on January 08, 2016, 07:06:14 pm
So we have to drain the whole unit, repair the sealings and fill up exactly with 1 L - G 004 000 fluid.

Thanks for the help, I hope we can fix it like this, because the +1400$ replace cost is too much.

Correct. Good luck!
Title: Re: DSG Mechatronics hydraulic fluid refilling
Post by: Silver on December 20, 2016, 11:38:46 am
Hello, i have the same problem with my mechatronic. Is leaking fluid and i have error that the oil pump doesn't work. So far the gearbox working good, so i am wondering if i replace the sealing it will work again without problem? Do you have any idea?
Title: Re: DSG Mechatronics hydraulic fluid refilling
Post by: Agwnistikotatos on March 20, 2017, 05:52:06 am
Hello,

I read here, http://www.vwwatercooled.com.au/forums/f112/7-speed-dsg-service-72463-2.html , that is possible to refill mechatronic from the top (breather hole). Is it true, or the only way is to turn is upside down and refill it from the drain plug?
Thank you.
Title: Re: DSG Mechatronics hydraulic fluid refilling
Post by: omeydz on March 20, 2017, 09:36:09 pm
refill through the top filler hole not the breathing vent or there will be airlock
Title: Re: DSG Mechatronics hydraulic fluid refilling
Post by: Agwnistikotatos on March 21, 2017, 09:08:53 am
refill through the top filler hole not the breathing vent or there will be airlock
I'm talking about mechatronic...
0CW's, have no filter anyway...
Title: Re: DSG Mechatronics hydraulic fluid refilling
Post by: standup1 on August 28, 2017, 07:21:47 pm
I am so glad I found this forum, it gave me some hope  :phew:. I have a problem with my golf 6 DSG 7. It is leaking from the Mechatronic, exactly from the breather cap. The dealer asked for over $2000 to fix it :rolleye: . Did anyone have same problem? Can I replace the breather cap? I've learned that filling up the Mechatronic is hard and needs some work, but I think I can deal with that part. I just don't know how to replace the breather cap! or how to stop the leak. Any help is very appreciated.
Title: Re: DSG Mechatronics hydraulic fluid refilling
Post by: DaveyLC on January 09, 2018, 04:43:57 pm
I recently purchased a Polo equipped with a 7 speed 0AM DSG box, after a while it started rough shifting and then eventually the transmittion fault light would show.

On inspection the Mechatronic unit was leaking hydraulic fluid at the rubber gasket.

As an intrim fix I worked out that the Mechatronic unit can be filled via the breather (it requires 1L of G004000M2 hydraulic fluid):


Eventually when I had time I removed the cover, cleaned up both surfaces and re-sealed it using a thin layer of LOCTITE black silicon gasket on both sides of the original rubber gasket..
(https://s13.postimg.org/iacdq7uw7/IMG_9083.jpg)

Its worth noting that when refitting be sure not to over-tighten the bolts as this can cause the cover to buckle and not seal correctly.

I hope this helps people :)
Title: Re: DSG Mechatronics hydraulic fluid refilling
Post by: alesypalsy on September 07, 2019, 01:29:15 pm
HI, new to this forum ,
I tried fixing hydraulic pump accumulator problem using the repair kit ,
When I refill I done from the breather hose and now believe I have air lock as the problem  was still there,
so I left overnight and this morning the pump gained enough pressure to stop working which was good news, my guess is over night the air came out,
but the problem is after I switch ff the car and try again the pump continually running again so I believe there is airlock in there!,
I then went on to drain the megatronic unit , remove starter motor and fill from the correct filler area,
Yet again the problem is still there,
any ideas how to get rid of the airlock or to get the hydraulic pump to get enough pressure t stop running!
I have spent 4 days on my golf now and I found good stuff on internet but the best stuff is in Russian and I cannot understand it!
thanks
Title: Re: DSG Mechatronics hydraulic fluid refilling
Post by: alesypalsy on September 09, 2019, 09:50:28 pm
Just to add to my last post, I today removed everything and found the O ring seal was squashed , which was stopping my accumulator hold pressure so it was not a airlock as I thought!
I got a new o ring and all is well now
Thanks