DSG vaihteiston korjaus

DSG clutch replacement

It should be noted that the clutch will be damaged by natural physical wear and tear. This process can only be slowed down by proper use of the car. Of course, the clutch can easily be "killed" by aggressive driving. The main symptoms for replacing the module are as follows:

Stiffness and slippage in clutch engagement when shifting gears
Loss of acceleration
Oil traces in the transmission housing.

When it comes to a "wet" clutch, it is appropriate to talk about repair, as usually only the friction discs are replaced, not the entire assembly. It is often wise to replace the dual-mass flywheel concurrently with the clutch replacement, as the lifespan of these components is approximately the same. When one of them is completely worn out, the other is also "on the verge." If the "failed" flywheel is not replaced, it will result in accelerated wear of the new clutch, additional damage to the transmission, and subsequent repairs.

Repair of DSG mechatronics.

The failure of mechatronics (control unit) usually occurs due to faults in other transmission components or irregular/poor maintenance. For example, dirty oil can clog the solenoids, or a stuck gear lever can cause a hydraulic explosion and so on.

Repair may be necessary based on the following main symptoms:

Clear jerks during gear shifting
Car jerking during starting and acceleration
Transmission goes into emergency mode and service key indicator lights up on the dashboard
Transmission no longer shifts gears, etc.

It should also be noted that sometimes it may be more reasonable to replace the mechatronics with a similar part from another car instead of repairing it. In this case, mandatory programming for the specific car is required.

What is DSG?

DSG, derived from the English term Direct Shift Gearbox or the German term Direkt Schalt Getriebe, is a family of dual-clutch automated manual transmissions. Why "pre-selective"? Because the transmission design combines two separate torque transfer circuits for even and odd gears. When power is transferred through one circuit, the other circuit also engages (for the next gear), but it spins freely. At the appropriate moment, torque is transferred to it. This allows for almost instantaneous gear shifts, resulting in optimal acceleration dynamics for the vehicle.

Essentially, in the design of a DSG transmission, engineers have managed to combine two mechanical gearboxes, with the gear shifting controlled by a management unit called the mechatronic. Of course, like any device, DSG transmissions have their advantages and disadvantages.

Types and models of DSG

Originally, this transmission was developed for the Volkswagen Group by Borg-Warner engineers (DSG-6 DQ250 with a "wet" clutch). Later, LUK joined the project, and together they developed and put into serial production the DSG-7 DQ200 with a "dry" clutch.

Currently, all types of DSG transmissions can be divided into "wet" and "dry" types based on the type and location of the clutch, as well as into 6-speed and 7-speed transmissions based on the number of gears.

Among them, only one gearbox has 6 gears and belongs to the "wet" type – the DSG-6 DQ250. The "dry" type is only found in the DSG-7 0AM / 0CW (DQ200). The rest are 7-speed transmissions with the clutch located in the common oil circuit of the gearbox, which means they are "wet".

What does DSG repair entail?

It should be noted that any VAG dual-clutch transmission (DSG) consists of three main components:

Mechanical part - the gearbox. This is the main part of the transmission, consisting of shafts, gears, bearings, gear shift forks, etc.
Clutch. This component is responsible for transmitting torque from the engine to the transmission.
Mechatronics. These are the electro-hydraulic "brains" of the DSG. It is this component that receives data from various sensors and controls the gear shifting and overall operation of the transmission.

Therefore, in each specific case, DSG repair may involve restoring various components. The list of components and their cost can only be determined through a thorough diagnostic process conducted by an experienced technician using specialized equipment.

VOLKSWAGEN PASSAT 2.0 TDI 2016