DIY DSG BOX REPAIR - WHAT TO LOOK FOR

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The robotic DSG gearbox, invented by the designers from the Volkswagen carmaker, has gained fame both very innovative and full of misunderstandings during its release. The fault of the latter, perhaps, was not only the engineering miscalculations of the developers, but also the inability of some drivers to handle such units. And the price of repairing such a checkpoint, as a rule, is considerable. And therefore, many motorists, who have at least a remote idea of the operation of the transmission, undertake the repair of the German "miracle of technology" on their own. However, how justified is this?

DSG Symptoms

Problems with this "robot" look pretty harmless at first. For example, a metallic knock during gear changes, grinding or any other extraneous sounds. Official dealers usually explain this behavior of the box by the peculiarities of its design, which makes the DSG more noisy compared to the classic "automatic" or the same manual transmission. And they agree to recognize the case as a guarantee, when tremors and shocks already take place.

If you enjoy the "pleasure" of driving with DSG, do not give a sharp start, sluggish acceleration, knocking when changing speeds, then the fault is probably in the clutch. The progressive slipping of its discs may well cause a breakdown.

It usually starts shaking the faulty gearbox in 2nd gear, when the gas pedal is released and a new set of travels at a low speed. This can happen, for example, during a detour around an obstacle.

The situation is more complicated when the box generally refuses to change gears. Restarting the motor may temporarily correct the problem. But in this case, the mechatronic control unit, the most expensive part in the DSG, will probably need to be repaired.

DSG Repair Tools

To restore the same mechatronic control unit, it is not necessary to take the vehicle to a workshop. Car enthusiasts can easily fix the DSG box on their own, but with the right tool. Without one, it is better not to undertake repairs yourself at all, so as not to "break the wood".

A seasoned car owner usually has a set of different keys and attachments in his "stash". Moreover, the tool can be useful both for six-star Torx sprockets, and for conventional hex mountings. Estimated prices for such "gadgets" are as follows:

set of imbus keys: from 80 rubles;
set of bits and socket heads: from 160 rubles;
a set of all kinds of screwdrivers, including Torx: from 270 rubles.

It is also advisable to have on hand special equipment - for example, a VAG-Com car scanner, which is sold at a price of about 1,000 rubles. This universal device allows not only to diagnose in detail the DSG gearbox, but also to reflash it, as well as to adapt the clutch. Having determined the range of problems with the checkpoint, you can start repairing it.

DSG: reboot

After purchasing a car with DSG or if there are any problems with the gearbox with the existing one, it is first of all recommended to check the version of the gearbox software. Even for relatively old cars, such as the Volkswagen Golf 6 1.6 DSG, similar firmware was released until 2017.

Moreover, it is advisable to check the firmware of not only the box, but also the engine. For example, from the causes of jerks in the mentioned Golf 6 when shifting from third gear to second, the software "aspirated" 1.6 BSE or gearbox cannot be excluded. Such a problem is completely eliminated by a complex flashing of the DSG and the motor. Other transmission pairs may have their own characteristics.

To eliminate some problems, it is enough to reprogram the gearbox or change the initial parameters taking into account the clutch damping. Replacing faulty sensors can also solve the problem. If neither one nor the other leads to the desired result, then a comprehensive diagnosis of the clutch and the mechatronic control unit is recommended, and, if necessary, a major overhaul of these units.

DSG repair features

Before dealing directly with the box, you should disconnect the battery terminals from it... At the same time, clean them if necessary. Next, use a hex wrench to unscrew the oil drain plug located on the gearbox housing. The seal on the plug is changed and the oil is drained.

Then you should unscrew the left and right "grenades", that is, drives on hinges of equal angular velocities. The bolts that secure the gearbox bell to the engine are also unscrewed. Finally, the box itself is removed from the car. In order to make it more convenient to unpack it further, the device is placed on a workbench or on a special stand.

In the mechanical part, the DSG has a lot in common with the manual transmission, therefore the next stage of repair will be very similar for them:

sequential dismantling of box shafts: leading, driven and intermediate;
removing gears from shafts;
troubleshooting of the disassembled box and replacement of worn-out parts with new ones.

In the mechatronic complex, most often the solenoids break down, or in other words, the solenoids located inside this unit. Therefore, it also needs to be disassembled. In addition to the parts that have failed, it is advisable to replace all the removed sealing elements in the block. Such repair kits are pre-procured. And the repair of the "robot" usually ends with the following steps:

assembly of the checkpoint;
installation of the gearbox on the car;
verification of DSG parameters and electronic functions;
general assessment of the gearbox performance on the machine.

By the way, upon completion of such a repair, it is recommended to check the wheels for wheel alignment.

DSG-7 clutch: price issue

The owner of a car with a DSG-7 gearbox, who decides to replace the clutch on his own, will first of all need a similar unit from LUK for Volkswagen, Scoda, Seat and Audi cars. Such a purchase will result in an amount of about 25 thousand rubles.

But that is not all. The DSG clutch block is mounted using a special tool kit, which costs about 90 thousand rubles. True, we are talking about original products under the LUK brand. The price, of course, is considerable, but such devices are characterized by a long service life.

Although the SAC clutch kit, also produced by the LUK manufacturer, has a price of only 15 thousand rubles, even though such a collection of tools is more modest. In principle, a skilled car enthusiast can do with the keys from the garage altogether. But the professionals don't advise.

Gearbox repair costs

Self-repair of the DSG box, although it allows you to save money, still entails costs, and sometimes considerable ones. The amount into which an undertaking may result will largely depend on the following factors:

type of malfunction and repair method;
scope of planned work;
list of unusable parts and their price;
availability and amount of unforeseen expenses.

The final price of such a repair can be established only after the box has been uncombined and the amount of work required has been determined. For example, a repair kit for a hydraulic plate of the Mechatronik complex will cost a motorist about 4,000 rubles, a set of solenoids - 8,000 rubles. Well, for the entire gearbox control unit, you will have to pay about 80 thousand rubles.

Finally, the replacement of the DSG box itself in the assembly will "pull" an average of 300-350 thousand rubles. Expensive, however.

DSG in practice

How justified is buying a car with a DSG gearbox? Here's what car enthusiasts have to say on this topic:

I got a "two-disk robot", which I do not regret. Before that, there was an automatic transmission with a torque converter. The cost of repairing a failed valve body was 70 thousand rubles. In the event of a DSG breakdown, the consequences will be similar. The new car has a five-year warranty, but when buying used equipment, it is useful to familiarize yourself with the history of the car, as well as the documentation on the maintenance of the gearbox and the replacement of the transmission fluid.Usually "mechanics" are cheaper, but here you have to choose between economy and comfort.
DSG - definitely! But only not "dry", as the wear of the clutch will not be long in coming: 80-90 thousand km - and a breakdown. And on the Volkswagen Passat, it is sometimes produced in general for 75 thousand km of run. It is much more comfortable to work in an oil bath of this part.
"Two-disk robot" or automatic transmission - the choice is not easy. Still, he preferred the second. Although DSG does not need special heating, but for a "hydro-automatic", on the contrary, it is better when the oil is hotter.
Perhaps, any checkpoint will have its own positive and negative properties. Which one to choose depends on the personal preference of the motorist. As for the "robot", it needs more careful maintenance than other gearboxes. You can safely buy a new DSG warranty. It would be nice to have time to sell this unit before it breaks down.
Damage to the mechatronic system or clutch is not something out of the ordinary for the DSG. And it's good if at the same time it is under warranty. So when a car is purchased for more than five years, it is desirable that it was with a manual transmission. Official dealers are not always willing to take on the repair of the "robot", sometimes it is easier for them to replace the entire gearbox. Such units, of course, are also repaired, but such a service usually costs about 100 thousand rubles.
If comfort matters, and finances allow, then buying a car is better with a DSG gearbox. "Gidroavtomat" with manual transmission can not be compared! Defects during the warranty period are not so bad. Moreover, the manufacturer has already significantly modified the "two-disk robot".

Conclusion

Although the DSG is complex in design, it is based on a conventional mechanical transmission with shafts and gears. Car enthusiasts undertake the repair of the "robot" themselves, most often when the warranty period for this unit has expired, and it is expensive to repair it in a workshop. But taking into account the prices for the equipment required to restore the checkpoint, it is still more profitable to take the car to a car service.