Replacing the DMF in a DSG

wrenchman30

Veteran Member
Joined
Oct 1, 2007
Location
arkansas
TDI
2005.5 gray 2006 dark blue
this is not a job for a novice. however if you choose to perform the replacement yourself i hope this helps. you will need a alignment afterwards. my drivers window didnt auto up for a couple of days. i left it down as i only have one key.
remove engine sound covers​
remove air box
remove battery and tray
remove air hose to turbo (screw faces up on intake side the rotate hose up towards hood till unlocked then pull towards driver side)
loosen left wheel
jack up and put on stands ( put left side behind jack about middle of driver door)
remove left wheel
remove skid plate
remove left inner fender
remove pendlum mount (bottom motor mount)
remove drive shaft bolts (lay shafts down and out of way)
loosen right support bolts about 1/4 inch
remove left support bolts (put jack stand under it to support)
remove left a arm nuts (pull down on a arm and disengage ball joint)
remove dogbone bolts and remove a arm and dogbone as a assembly
remove lower tranny bolts (ones in oil pan also 3 total with 16mm heads)
go to top of engine
remove starter (if you have blowgun blow off top of tranny)
remove tranny plug in remove heat exchanger (cover hole with clean rag)
bend heat exchanger hoses over and lock behind air intake at radiator and cover with rag
support engine with jack (use two by four between jack and oil pan) jack needs to be on rearmost of oil pan
remover rear motor mount and bracket on top of tranny
remove shifter cable (i remove bolt and the c clip and pulled out)
remove all but one of tranny bolts (one hidden in starter hole) 18mm head
hook up engine hoist to tranny
remove last tranny bolt
wiggle tranny out to driver side area towards firewall for clearance
lower tranny to ground
remove flywheel bolts and flywheel
reinstall in reverse order.
 
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wrenchman30

Veteran Member
Joined
Oct 1, 2007
Location
arkansas
TDI
2005.5 gray 2006 dark blue
i used paint program to edit the photos. sorry the wording isnt larger
 
Last edited:

wrenchman30

Veteran Member
Joined
Oct 1, 2007
Location
arkansas
TDI
2005.5 gray 2006 dark blue
i fought getting the tranny out without loosining the suspension so it took longer than it should. i would think you could do it in 3 to 5 hours. i had to buy some tools. i had bought a socket set but they werent the triple square drive that is required. i had 7 to 8 hours total in the job.
 

gquenstedt

Veteran Member
Joined
May 26, 2006
Location
San Antonio, TX
TDI
'06, '03 x 2, '00
wrenchman30 said:
i fought getting the tranny out without loosining the suspension so it took longer than it should. i would think you could do it in 3 to 5 hours. i had to buy some tools. i had bought a socket set but they werent the triple square drive that is required. i had 7 to 8 hours total in the job.
7 to 8 hours just to remove it or to remove and install?
 

bombero

Veteran Member
Joined
May 14, 2006
Location
The Lone Star State
TDI
2006 Jetta TDI
Where did you buy the SMF for the car? I have not seen one for sale for the DSG models. Did it come in a kit with everything necessary included?
 

wrenchman30

Veteran Member
Joined
Oct 1, 2007
Location
arkansas
TDI
2005.5 gray 2006 dark blue
i had to reinstall the updated DMF bobero. if i couldve found a smf i wouldve. qq i had about 8 hours to remove and install it. from running to down and back to running.
 

TonyJetta

Top Post Dawg
Joined
Sep 15, 2005
Location
Tucson, Az
TDI
'15 Jetta TDI SE / '06 Jetta TDI DSG Pkg0 / '96 Passat TDI
wrenchman30 said:
loosen right support bolts about 1/4 inch
remove left support bolts (put jack stand under it to support)
...
remove lower tranny bolts (ones in oil pan also 3 total with 16mm heads)
...
remover rear motor mount and bracket on top of tranny
...
remove all but one of tranny bolts (one hidden in starter hole) 18mm head
Are any of these TTY / one time use bolts?

I think my Jetta needs the DMF replaced.

TIA

Tony
 

Mach1

Vendor , w/Business number
Joined
Sep 27, 2005
Location
Spicewood, Tx.
TDI
05.5 Jetta 5 spd, 06 Jetta DE DSG, 04 F250 6L, 2000 F250 7.3L
I would say that a front end alignment would be in store for this job to be complete and yes, A lot of TTY fasteners to be replaced if you go by the book(VW wouldn't replace them).

Good write up.
 

TonyJetta

Top Post Dawg
Joined
Sep 15, 2005
Location
Tucson, Az
TDI
'15 Jetta TDI SE / '06 Jetta TDI DSG Pkg0 / '96 Passat TDI
Just changed the flywheel thursday-friday. Yes, I know others would have been quicker, but I was trying to be through. All worked out well, and noise is gone.

In my case, the noise was more like a scratch or soft grind at cold idle. It's gone now! ;)

Some tips: Buy the metalnerd triple-square set, and the 14mm triple square socket. You'll need it for the upper transmission-engine bolts. You'll also need box-wrench-socket-adapters for a few locations. 1) the upper trans bolts, and 2) one of the lower transmission bolts.

Oh, and be prepared to replace the following stretch hardware:
1) Trans mount
2) Pendulum mount
3) Control Arm mount
4) Any subframe mount bolts that you loosen.

Take your time, and follow wrenchman's write up. It's quite accurate, sans the torque values.

Tony
 

Mach1

Vendor , w/Business number
Joined
Sep 27, 2005
Location
Spicewood, Tx.
TDI
05.5 Jetta 5 spd, 06 Jetta DE DSG, 04 F250 6L, 2000 F250 7.3L
This is funny--book time for waranty work is less then 4 hours..to R&R DSG. Real funny, no wonder they cant keep techs.
 

maloosheck

Veteran Member
Joined
Jan 9, 2006
Location
Sterling, VA
TDI
2K6 1K2 BRM, 2K8 7L6 BWF, 85 16 MF
Why did you remove the suspension arm? When I was replacing my DMF in 5MT I did not touch the suspension. Is DSG larger?
 

TonyJetta

Top Post Dawg
Joined
Sep 15, 2005
Location
Tucson, Az
TDI
'15 Jetta TDI SE / '06 Jetta TDI DSG Pkg0 / '96 Passat TDI
Yes, afaik the DSG is a little larger; you need to clear the diff housing.
 

wrenchman30

Veteran Member
Joined
Oct 1, 2007
Location
arkansas
TDI
2005.5 gray 2006 dark blue
sorry guys have been playing world of warcraft and dont go anywhere else much anymore. i did try to not move the suspension. hate getting alignments redone. after a couple pretty sure i could do book time. or less. but i do it for a living. hope it helps someone.
 

TonyJetta

Top Post Dawg
Joined
Sep 15, 2005
Location
Tucson, Az
TDI
'15 Jetta TDI SE / '06 Jetta TDI DSG Pkg0 / '96 Passat TDI
wrenchman30 said:
...i did try to not move the suspension. hate getting alignments redone....
If you can find a firestone store in your area, you can buy a lifetime alignment for ~$140

I take both VW's in 2x per year to check alignment.

Tony
 
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