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DSG Mechatronic Replacement (2004 Audi TT 3.2L)

5.7K views 20 replies 7 participants last post by  CaptRon  
#1 ·
Hello Gang!

Here's my experience with 02E Mechatronic replacement. To make a long story short this original DSG was acting up once the tranny is warm up. Sluggish 1st gear engagement from stop and go. Massive slipping on all gears. Finally it died with flashing PRNDS. Dealer want anywhere from $2500-$3000 for mechatronic replacement. Went ahead and order a new unit and had it replaced along with various covers and bolts. I took my time and it took a good 10 hours. Hope this help someone on the forum to do it themselves :).

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10hrs mess :D

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Side note: ECS Tuning had to special order from Germany ($1500). They made me wait a month then on delivery date told me that Audi of Europe told them it's back order - WTF ECS!!! I love ECS but this time they really did a faceplant. I was quite desperate for a new Mech and reach out to Wil Auken at World Impex. He was really helpful and got me a Mech in just a few days.

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Main connector for Mechatronic: To release use a screw driver and pry lever to the right.

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Need to drain all DSG fluid for this job.

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On TT 3.2L this support cross bar need to be remove in order to make room.

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I had to disconnect AC line and coolant to make remove support cross bar (last pic). Stupid me just disconnect the AC line and it blew the hose right off. Massive amount of pressure came out from the freon inside. Don't do what I did!!! Coolant line was easy but messy.

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To make even more room you'll have to remove the engine mount and pull it back a few inches. Last thing I want is not having enough room and break the new Mechatronic sensor arm.

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Here's another view. Doesn't seem like much room but just enough to work.

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Here's the beast. Side cover is removed so you can see what you're doing with that black sensor arm.

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Close up! :D

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Everything is the same except for the electrical backside.

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To install: Start by holding the Mech 90 degrees to the left. Insert the sensor arm but don't push it in yet. Rotate 90 degrees to the right while sliding it in. Removal is just the reverse. Nearly **** my pants trying to put in the new Mechatronic :facepalm:. Use new bolts and torque them all to specs.

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I use top fill method and Ross-Tech up to temp to drain excess fluid.

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Performed Adaptation with Ross-Tech. Google "dsg adaptation" for procedure.

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So happy everything went smoothly. She runs perfectly now!
 
#2 ·
Good job !

The only thing is that removing A/C line is not mandatory to remove support cross bar (done twice without opening A/C circuit).
 
#4 ·
matt31 said:
Good job !

The only thing is that removing A/C line is not mandatory to remove support cross bar (done twice without opening A/C circuit).
Thank you! Is there a trick? I couldn't move it when i had to replace my fan.
 
#7 ·
loremipsum said:
matt31 said:
Good job !

The only thing is that removing A/C line is not mandatory to remove support cross bar (done twice without opening A/C circuit).
Thank you! Is there a trick? I couldn't move it when i had to replace my fan.
No specific trick. Unbolt it and move it until you find the solution to take it out of the car...
 
#9 ·
I'm wondering if a second generation (MKII) Mechatronic would be be a straight fit on our cars. My A3 is also a DSG and I find the gearbox to work much better then on my TT.
 
#11 ·
rusTTy_racer said:
OP - Great work and excellent pictures :p

2 Questions... were you a bit nervous fitting an older version than what you had already? (was this a re con unit?)
who makes the oil filler/funnel?

Thanks :)
Hi, My bad I need to clarify. I don't know whats originally came with the car. Even afrer taken it out all the part number on it didn't match at all to what was known as DSG part number. I end up settling for the 2nd latest revision based in a prt number a dealer given to me.

The funnel is some rebranded Chinese made. I got mine from Advance Auto Parts (Connecticut US)
 
#12 ·
CaptRon said:
I'm wondering if a second generation (MKII) Mechatronic would be be a straight fit on our cars. My A3 is also a DSG and I find the gearbox to work much better then on my TT.
I like to know that too. If that is true I would have gotten the latest Mech. I couldn't find anything definitive out there for which Mech work/wont work with which car.

Can you tell me how the A3 DSG works better? Which year is this?

Thanks
 
#13 ·
woodencowboy said:
Is your A3 a 3.2? This would surely be an interesting proposition but I wonder what the benefits would be over the mk1? Has anyone had extensive use of both a 3.2 mk1 and a mk2 3.2 engine be it R32, TT or A3? Not sure if the A4 3.2 was mated to the dsg?
I wish. Doesnt seem like anyone know this stuff. Not even the dealer.
 
#14 ·
loremipsum said:
CaptRon said:
I'm wondering if a second generation (MKII) Mechatronic would be be a straight fit on our cars. My A3 is also a DSG and I find the gearbox to work much better then on my TT.
I like to know that too. If that is true I would have gotten the latest Mech. I couldn't find anything definitive out there for which Mech work/wont work with which car.

Can you tell me how the A3 DSG works better? Which year is this?

Thanks
My As is a 2007 with the 2.0L engine and my TT is a 2005. I found that when accelerating from a full stop my A3 always take off more smoothly and without hesitation as my TT seems to slip when starting from cold to occasionally more abrupt start when warm. Maybe it's just that my TT has a mechatronic issue. There was a recall for my A3 and the DSG has been replaced and it's been working very well since.

Steve (V6RUL) has installed a newer mechatronic on his car but I don't know if he hadn't replaced the gearbox as well.
 
#15 ·
Mech units are similar on several models (all pre-2008 have similar mech units if I correctly remember). BUT the software loaded is developped for each model. Last revision on TT 3.2 is 0857 version, already available since end of 2005.
You cannot install A3 mech unit without flashing it with 0857 software or earlier developped for the TT 3.2.
 
#16 ·
matt31 said:
Mech units are similar on several models (all pre-2008 have similar mech units if I correctly remember). BUT the software loaded is developped for each model. Last revision on TT 3.2 is 0857 version, already available since end of 2005.
You cannot install A3 mech unit without flashing it with 0857 software or earlier developped for the TT 3.2.
Merci Matt,, I knew you would know the answer!
 
#17 ·
You're welcome ! I try to share the little knowledge accumulated during the past years on this model... Moreover, it seems that all brand new mech units installed on our TT is the same reference since mine has been replaced by Audi in 2012.
We can maybe call it a mature version...
Last revision is 02E325025AD.
 
#18 ·
Any 3.2 mech unit will work across the Audi range as long as the software is flashed over to suit the car your running.
I have run mk1 DSG with mk1 & mk2 mechatronics.
Mk2 mechatronics had component revisions in 2008 for better lifespan, from lessons learnt from mk1 DSG mech units.
On my TT I now run a VW R36 modified DSG with MK2 Audi TT mechatronic unit, which is more complicated to do as the operating software has to be flashed over as well as the platform software.
Very few tuners/calibration companies do these changes, but mine did as part of a HPA upgrade.
Steve
 
#19 ·
V6RUL said:
Any 3.2 mech unit will work across the Audi range as long as the software is flashed over to suit the car your running.
I have run mk1 DSG with mk1 & mk2 mechatronics.
Mk2 mechatronics had component revisions in 2008 for better lifespan, from lessons learnt from mk1 DSG mech units.
On my TT I now run a VW R36 modified DSG with MK2 Audi TT mechatronic unit, which is more complicated to do as the operating software has to be flashed over as well as the platform software.
Very few tuners/calibration companies do these changes, but mine did as part of a HPA upgrade.
Steve
Hey Steve, Thanks for the info. I'm looking to go HPA route as well once I get some funding. Just a quick question... Do you know if TCU flash upgrade from major chip company will update the DSG software to latest version beside "improving" some parameters?
 
#20 ·
loremipsum said:
V6RUL said:
Any 3.2 mech unit will work across the Audi range as long as the software is flashed over to suit the car your running.
I have run mk1 DSG with mk1 & mk2 mechatronics.
Mk2 mechatronics had component revisions in 2008 for better lifespan, from lessons learnt from mk1 DSG mech units.
On my TT I now run a VW R36 modified DSG with MK2 Audi TT mechatronic unit, which is more complicated to do as the operating software has to be flashed over as well as the platform software.
Very few tuners/calibration companies do these changes, but mine did as part of a HPA upgrade.
Steve
Hey Steve, Thanks for the info. I'm looking to go HPA route as well once I get some funding. Just a quick question... Do you know if TCU flash upgrade from major chip company will update the DSG software to latest version beside "improving" some parameters?
Hi,
the software revisions from Audi will only affect driving a fraction of a % and may not even be noticeable.
A generic flash from a calibration company will give you a set of modified driving parameters.
A custom map will change parameters according to your request providing they are feasible.
Steve
 
#21 ·
V6RUL said:
Any 3.2 mech unit will work across the Audi range as long as the software is flashed over to suit the car your running.
I have run mk1 DSG with mk1 & mk2 mechatronics.
Mk2 mechatronics had component revisions in 2008 for better lifespan, from lessons learnt from mk1 DSG mech units.
On my TT I now run a VW R36 modified DSG with MK2 Audi TT mechatronic unit, which is more complicated to do as the operating software has to be flashed over as well as the platform software.
Very few tuners/calibration companies do these changes, but mine did as part of a HPA upgrade.
Steve
Hi Steve, I was hoping to hear from you on that subject... this is very good to know Thanks!