To help any DIYers that are attempting replace their DL382 transmission DSG filters and fluid, we've made this extensive step by step guide.
Replacing the filters and fluid in the DL382 transmission properly is not incredibly difficult, but it does take time to perform the service properly. In fact, the filter replacement portion of the service can be finished in less than 15 minutes. Most of the time spent involves removing the mechatronic/valve body and re-installing it into the transmission.
Time Required
I'm not going to sugar coat this part; this is a time intensive service. Be prepared to dedicate a good chunk of a day to perform this service correctly. For the average DIYer, it can easily take over 8 hours to complete this service properly.
Parts Required
This guide is assuming you are using one of our DSG filter service kits. Our kits include all of the same parts that our service department uses when performing a filter replacement service on a DL382 transmission. Here's a breakdown of all of the parts you should have to do the service:
Filters
- 1x 0CK325121D Low Pressure DSG Filter
- 1x 0CK325149D High Pressure DSG Filter
- 1x 0CK325421A Suction DSG Filter with O-rings
Fluids
- 5 Liters of LIQUI MOLY 8100 DSG Fluid (or equivalent DSG fluid)
Gaskets/Seals
- 1x High Pressure DSG Filter O-Ring
- 1x Low Pressure DSG Filter O-Ring
- 1x 0CK325443 Mechatronic Unit Seal
- 1x 0CK325444 Mechatronic Unit Seal
- 1x 0CK325445 Mechatronic Unit Seal
- 1x 0CK325446 Mechatronic Unit Seal
- 1x 0CK321371A Transmission Pan Gasket
0CK927523 Mechatronic Connector Seal
The mechatronic connector seal installs between the mechatronic unit and the transmission housing. If there is a leak at the mechatronic connector, Audi recommends using two seals to prevent further leaks.
Hardware
- 2x 0CK321439A DSG Drain/Fill Plugs
- 1x 0CK325107F Transmission Pan Tube
- 7x N10739402 Mechatronic Unit Mounting Bolts
- 7x N10787901 High Pressure and Low Pressure Filter Housing Bolts
- 2x N10787701 Suction Filter Bolts
- 4x N91126101 Transmission Cooler Mounting Bolts
- 25x N10156207 Transmission Pan Bolts
Software Required
In order to properly change the fluid in the DL382 transmission, you will need to use specific software. Both VCDS and OBD11 have functions that will allow you perform this service. Since we primarily use VCDS, our instructions will be based on using it.
Tools Required
You will need a variety of tools to complete this service including several metric sockets, Torx bits and triple squares. Most of the bolts and nuts you'll be removing are fairly accessible from underneath the vehicle, but having a few extensions is necessary. Make sure you have a good ratchet wrench and a properly calibrated torque wrench as well.
You'll also need something to catch the old DSG fluid and a transmission fluid pump to put the new fluid into the transmission. These pumps can easily be found on Amazon or at your local automotive parts store. To connect the pump to your transmission for proper filling, I highly recommend getting a VAS6617/12 transmission fluid adapter.
Finally, you will also need a good pick set with at least one long pick to disconnect a very hard to reach electrical connector inside the transmission housing.
Wrench:
- 18mm
Sockets:
- 10mm
- 13mm
- 17mm
- 18mm
Triple Squares:
- M12
- M14
Torx Bits:
- T25
- T30
- T30 Plus
Cooldown May Be Required
If you have recently driven the vehicle, you will need to let the transmission cool down before attempting a fluid change. This can take a few hours if you live in an area with hotter temperatures.
MTF Fluid Service Suggestion
Since you're already going to be under the transmission, this is a good time to change the MTF fluid. There is no replaceable hardware, so all you will need to perform this service is the fluid itself and a fluid pump to fill the section. Draining the MTF section simply involves removing the four bolts that hold in the MTF fluid pump. The fluid is drained by removing this pump. I highly recommend collecting the fluid and measuring it so you know exactly how much fluid when re-filling the the MTF section.
There is no replacement seal available for this pump, so make sure to clean it and set it aside for re-assembly. Once the MTF fluid has been drained, simply re-install the pump and fill it using the fill plug on the side of the transmission. The MTF section will typically take between 3.4 and 3.8 liters of fluid.
It's important not to over-fill this section since the DSG section and the MTF section share a breather hole. If you overfill the MTF section, it can get into the DSG section and contaminate the DSG fluid. If this happens, it can cause damage to the transmission!
Please check to make sure that you have all of the necessary gaskets/seals, filters and hardware BEFORE starting this service. You don't want to get halfway through only to realize you are missing something.
1. Remove Belly Pan/Splash Shields
There are several different screws/bolts used to install the belly pan/splash shields. I highly recommend separating them and writing yourself a note on which hardware goes to which section so you don't mix them up when it comes time to reinstall them. Trust me, it will save you some headaches.
2. Remove Subframe and Disconnect Lower Control Arms
3. Drain DSG Fluid
To properly drain the correct amount of fluid for this service, the fluid temperature must be between 30° C and 50° C (86° F and 122° F). If the transmission is cold, you'll need to start the engine and let it idle for a few minutes. While it's running, use VCDS (or OBD11) and pull up the transmission control module (Address 02), select measuring blocks and find transmission fluid temperature. After the correct temperature is achieved, shut off the car, remove the drain plug and drain the fluid.
Once the fluid stops coming out, you must perform an ATF Drain Adaptation. This adaptation will empty the pressure accumulator so that the maximum amount of fluid is drained from the transmission. Please visit this page for instructions on how to drain the pressure accumulator using VCDS (see section on ATF Drain, Fill and Level Check). It can take a few minutes for the pressure to fully discharge, so feel free to grab a sandwich while you wait.
After the the ATF Drain Adaptation has completed, you can turn the car off.
Please note that you must turn off the ATF Drain Adaptation in order to later fill the transmission with the new fluid.
4. Remove Transmission Cooler
Remove the transmission cooler bracket by unbolting it. The bracket is located at the end of the cooler furthest from the transmission pan.
Next, remove the two bolts that hold the transmission cooler to the transmission pan.
Once the bracket has been removed and the transmission cooler has been un-bolted from the pan, carefully slide the transmission cooler away from the transmission pan. Fluid will drain out of the cooler, so make sure you have something to catch it. Use a bungee cord or strap to hold the cooler out of the way.
There is a two piece tube that connects the transmission pan to the cooler. If you purchased our DL382 ultimate service kit, it will come with a new tube, so keeping the old one isn't necessary. If you didn't purchase our kit and don't have a replacement, be careful not to damage any of the tabs on the tube when removing it. Also make sure to note the orientation of the tube for reference when putting everything back together.
5. Remove Transmission Pan
To remove the transmission pan, simply remove all of the bolts. There are 25 of them located around the perimeter of the pan. Your vehicle might be equipped with aluminum bolts. We have found that this hardware can easily break, so please go slow when removing them.
Once the pan has been removed, you can now see the mechatronic unit/valve body in all of its glory.
6. Remove Mechatronic Unit/Valve Body
There are seven bolts that hold the mechatronic unit/valve body into the transmission. You'll want to leave one of the bolts in and have a second set of hands to lower the mechatronic unit/valve body from the transmission when you remove the final bolt.
Before you fully remove the mechatronic unit/valve body, you'll need to disconnect a wiring harness from inside the transmission housing. Due to it's location within the housing, this can be somewhat tricky to reach. We recommend using a long pick tool to release the connector.
Once you've done that, slowly lower the mechatronic unit/valve body from the transmission housing.
I highly recommend placing a large piece of scrap cardboard wherever you plan on working on the mechatronic unit/valve body assembly. This will help to soak up any excess DSG fluid.
7. Partially Disassemble Mechatronic Unit/Valve Body
You've probably noticed that there's a lot going on with the mechatronic unit/valve body assembly. Lets break down the components you'll be replacing:
Remove the suction filter and the mechatronic unit gaskets. There are 4 of these gaskets. The suction filter has two bolts holding it in.
Next, remove the three bolts holding the high pressure filter housing in place. This is the smallest vertical filter housing (on the right side if you are using our photos as reference). It has a metal locking ring holding the filter housing to the mechatronic unit. Take off the plastic housing, set it aside and remove the filter.
Finally, remove the four bolts holding the low pressure filter housing to the mechatronic unit (on the left side if you are using our photos as reference). Take off the housing, set it aside and remove the filter.
Take a moment to inspect the old filters. It's normal for the filters to be fairly dark and dirty. It's also common for the high pressure filter to expand over time.
8. Clean Everything
Once you have everything disassembled, you must fully clean the mechatronic unit/valve body and the filter housings. We recommend using a low VOC brake parts cleaner to do this. You shouldn't need to scrub anything down. Just make sure that all of the old DSG fluid is fully cleaned from the parts.
We also recommend spraying down the inside of the transmission housing and cleaning all of the mounting surfaces for the mechatronic unit/valve body and the transmission pan. This ensures a good seal when re-installing everything. Make sure to clean the magnets on the transmission pan as well.
9. Install New Filters and O-Rings
The filters can only be installed in one direction in their respective locations, so it's fairly difficult to screw this part up. We recommend using some assembly lube on the O-rings to ensure they seat properly when pushing the filters into place.
Once you've installed the low pressure and high pressure filters, simply replace their respective plastic housings/covers. For the high pressure filter housing, remember to re-install the metal locking ring. Once you've done this, install the hardware and hand tighten it. Then use the following tightening sequence and torque specs:
- High Pressure Filter Hardware: 8 Nm + 90° Additional Turn
- Low Pressure Filter Hardware: 8 Nm + 60° Additional Turn
Next, you'll install the new suction filter. Once again, use some re-assembly lube on the O-rings first.
Once you've done this, install the hardware and hand tighten it. Then torque them down to 8 Nm + 60° additional turn.
10. Install New Mechatronic Unit Seals
This is very straight forward as the mechatronic unit seals are all different and will only install into their respective locations.
The mechatronic unit connector seal(s) simply install into the slots on connector shaft. There will be two slots. If you found that fluid was leaking past the original seal, you should add a second new seal into the open slot.
If you assembled everything correctly, your mechatronic unit/valve body assembly should now look like this:
11. Re-Install Mechatronic Unit/Valve Body
Very carefully lift the mechatronic Unit/valve body assembly and position it into the transmission. Be careful not to force it into place. If you have it aligned properly, it will easily go back in without much effort. Make sure to hold the wiring harness out of the way as you do this so that it doesn't get pinched in the housing.
Hand thread bolt one of the mechatronic unit/valve body mounting bolts into the center hole so that it is holding the mechatronic unit/valve body in place in the transmission.
Next, install the rest of the mounting bolts and hand tighten them. Once you've done that, torque them down 8 Nm + 120° additional turn in the following sequence:
12. Re-Install Transmission Pan
Make sure that the transmission is completely clean and dry, then install your new transmission pan gasket.
Next, install the transmission pan and hand tighten all of the pan bolts. Then torque the hardware down using the following sequence to 8 Nm + 90° additional turn.:
Tightening the new hardware in the correct sequence is imperative to ensuring a proper seal to the transmission. Failure to do this can lead to the pan leaking at the gasket.
13. Re-Install Transmission Cooler
Install your new transmission pan tube and fit the transmission cooler connector over the end of it. Install the two bolts that hold the transmission cooler to the pan and tighten them.
Next, re-install the transmission cooler bracket and hardware. Torque the hardware to 3 Nm + 60° additional turn.
14. Add New DSG Fluid
Before filling the transmission with fluid, make sure you turn off the ATF Drain Adaptation!
Install a new drain plug and fill the transmission. Typically the transmission will take roughly 4.35 liters since it has been completely emptied of all fluid. Do NOT install the new fill plug yet.
Turn on the vehicle and let it idle to bring the transmission up to temp. Using VCDS or OBD11, pull up the transmission control module (Address 02), select measuring blocks and find transmission fluid temperature. Once the transmission fluid temperature is between 30° C and 50° C (86° F and 122° F), check the DSG fluid fill hole. You should see a small amount of fluid coming out if the correct amount of fluid was used. If you don't see any fluid coming out, keep adding more in very small amounts until it starts to seep out of the hole.
15. Re-install Subframe
Please follow the instructions below to properly re-install the subframe hardware.
Install all of the hardware by hand. Then, tighten the hardware diagonally in stages. Please note that bolts 1 and 2 in the illustration above must be tightened last. Continue tightening the bolts diagonally in pairs until they've all been properly torqued to the following specs.
- 90 Nm + 90° additional turn
- 90 Nm + 90° additional turn
- 40 Nm
- Subframe assembly
- 115 Nm + 180° additional turn
- Subframe assembly
- 9 Nm
- Shield
- 9 Nm
- Steering rack
- 115 Nm + 180° additional turn
- 50 Nm + 90° additional turn
- Clip
16. Re-install Belly Pan/Splash Shield
Use the original hardware to re-install the belly pan and splash shield. Make sure to use the appropriate hardware for the correct sections.
17. Set Clutch Slip Point Adaptation
Using VCDS (or OBDEleven), you'll need to set the new clutch slip points.
Select the automatic transmission control module (address 02). Then choose basic settings. Then select: IDE02298-ENG164656 - Adaptation of clutch kiss points from the list. Click start and wait for it to finish the adaptation process. It will display "Finished Correctly" once it has properly completed the adaptation of the clutch slip points.
18. Test Drive
After you've performed this adaptation, you'll need to test drive the vehicle. Drive the car with the transmission in "drive" mode and let the car shift up through all 7 gears and back down again. Then put the transmission into "sport" mode and do the same thing. Finally, put the transmission into "manual" mode and go through the gears one final time.
At this point you should hopefully have a smooth driving Audi. Each shift should feel nice and crisp.
If you have any questions regarding this service, please feel free to contact us. One of our in-house experts will be happy to assist you.