New developments in the field of automatic transmissions give the car enthusiast great opportunities for selection. And with the advent of a robotic box on the market DSG gears making a choice becomes more and more difficult - you want to try everything to find the best for yourself. DSG is a new generation gearbox that combines all the best engineering solutions and modern technologies. In the article we will analyze its structure, characteristics, types, including recommendations for operation.

DSG gearbox

DSG selector

The DSG gearbox (from German: Direkt Schalt Getriebe) was developed German concern Volkswagen. Literally, DSG is translated from German as: “direct gearbox.” The transmission is a type of robotic gearbox using a double clutch, combining the characteristics of both automatic and manual transmissions. The process of shifting gears and engaging/disengaging the clutch occurs automatically, and the driver only selects the desired driving mode using the gear selector lever.

DSG has long proven itself with positive side in cars sports type, and for ordinary Vehicle is still a new product. Another name for the transmission is a preselective dual-clutch robotic gearbox. It is the presence of two clutches that distinguishes this type of automatic transmission from its other counterparts.

Design and principle of operation

DSG preselective gearbox device

Automatic transmission device of this type following:

• main gear and differential;
• Mechatronic control module;
• dual clutch;
• internal input shaft;
• outer input shaft;
• two secondary shafts.

The design feature of the DSG is that it has two primary and two secondary shafts. Each secondary shaft is in mesh with its corresponding primary shaft. Moreover, on one pair of shafts there are gears of even gears, and on the other - odd ones. The input shaft with even-numbered gears is made hollow and the input shaft of odd-numbered gears is inserted into it. Each shaft is connected to its own clutch.

Gear shifting occurs as follows: the car begins to move in first gear, but second gear is already in “combat readiness,” that is, its gears are already in mesh. As soon as the command to shift to second gear is received, the odd clutch will open and the even clutch will close. In this case, the third gear is already engaged in the odd numbered row in order to begin work immediately after the even clutch is opened. Gear shifting is carried out using synchronizers.

Thus, gears are changed at a speed that is beyond the reach of even the most experienced driver. Hence the name preselective gearbox (pre - in advance, select - choice). Scientifically speaking, thanks to this, the DSG gearbox has virtually no interruption in the power flow from the engine to the gearbox when changing gears. This has a positive effect on both vehicle acceleration and fuel efficiency.

The clutch and gear shifting are controlled by the control unit. It consists of electronic and hydraulic control modules, as well as sensors. This unit, called Mechatronic, is located directly in the gearbox housing.

Built-in sensors monitor the condition of the gearbox and monitor the operation of the main elements. Monitored parameters: rotation speed at the input and output of the gearbox, oil pressure and temperature levels, position of the gear shift forks. Based on sensor signals, Mechatronic implements a transmission control algorithm.

Varieties of DSG

Currently, there are two types of DSG gearbox:

• six-speed;
• seven-speed.

General scheme 6 and 7 speed DSG

Initially, the preselective automatic transmission was six-speed. It uses a wet-type double clutch (in everyday life - “wet”). The clutch is constantly in oil, which provides lubrication of the parts and cooling of the discs, which, in turn, increases its service life.

Unlike the six-speed gearbox, the clutch of the 7-speed DSG is “dry”, and this automatic transmission requires three times less oil. Oil pump with hydraulic drive replaced here with an electric one, which reduces energy consumption and increases the fuel efficiency of the engine. But the clutch resource will be lower.

DSG 6 transmission

The DSG 6 automatic transmission is not the latest model in a series of robotic transmissions from Volkswagen. But it is considered more powerful - the engine torque is 350 Nm.

Today this gearbox is installed on cars of the following brands:

• Volkswagen (Golf, Passat, Jetta, Touran, Tiguan);
• Skoda (Superb, Octavia);
• Audi (A3, Q3, TT);
• Seat (Toledo, Alhambra).

Transmission DSG 7

The seventh DSG model appeared three years after the sixth and was made specifically for budget cars. DSG 6 is distinguished by its large weight (about 95 kilograms) and a large volume of gear oil. DSG 7 weighs about 70 kilograms and has a smaller oil volume, which has a positive effect on fuel consumption and the cost of regular maintenance.

7-speed DSG device

DSG 7 is installed on cars equipped with an engine with a torque of up to 250 Nm. These include the following models:

• Volkswagen (Golf, Passat, Transporter, Caddy);
• Skoda (Fabia, Superb, Octavia);
• Audi (A3, Q3, TT);
• Seat (Ibiza, Leon, Altea).

The design of a “dry” DSG is no different from a “wet” one. It is based on: the first and second secondary shafts, the main gear, oil filter, flywheel and Mechatronics unit. A special feature of this automatic transmission is the presence of two dry friction clutches that do not operate in an oil bath. This technical innovation allowed to significantly increase the efficiency of the box.

Differences between the two generations of DSG

The DSG automatic transmission is undoubtedly one of the most advanced gearboxes. But, despite the obvious advantages, it also has disadvantages. Let's analyze them in more detail, while paying special attention to both “wet” and “dry” automatic transmissions.

DSG 7 gearbox

The main difference in the DSG of the two generations is determined by the amount of transmitted torque. This is due to the type of cars on which the boxes are installed. The weight of the box, oil consumption and fuel efficiency have already been written above. The seventh model will be better in this regard. But a longer service life and higher reliability will be provided by a six-speed gearbox.

Now let’s talk directly about what advantages characterize the DSG automatic transmission.

1. Fast gear shifting.
2. High acceleration dynamics due to the almost continuous supply of torque to the car’s wheels.
3. Smooth movement of the car due to the fact that gear shifting occurs without jerking.
4. The ability to operate in both automatic and manual gear shift modes, which gives the driver the opportunity to independently choose his driving style.

Now as for negative qualities DSG.

1. The overall complexity of the design and, as a result, an increase in the overall cost of the vehicle, as well as a decrease in service life.
2. Difficulty of repair.
3. Expensive and difficult to change the oil, especially in the six-speed DSG.
4. With DSG 7, the process of shifting up or down may not be as smooth. This is due to the peculiarities of the dry clutch.
5. It is inconvenient to operate a car in traffic jams, since when stopping it is recommended to switch to neutral gear.

Many modern cars equipped with a DSG gearbox. It is installed on passenger cars B and C class. It can also be found in cars of class D and higher (a six-speed type of product is installed on powerful cars). Therefore, car owners want to know what a DSG gearbox is and how it differs from its manual and automatic predecessors.

The DSG gearbox is a robotic unit equipped with two clutches and two rows of gears associated with them. This modern device is available in six-speed and seven-speed versions.

DSG structure

• double clutch;
• final drive;
• two rows of gears;
• differential;
• dual mass flywheel;
• control system.

How DSG works

This gearbox sequentially includes gears of two rows. That is, when one of the gears is operating, the next one is always selected, which means it is ready for use. This operating scheme ensures switching without interruption of the power flow. This significantly increases the capabilities of the box compared to its mechanical and automatic counterparts. After all, an engine with such a gearbox does not run idle, fuel is consumed much more slowly, and the car receives improved acceleration characteristics.

Design of six- and seven-speed DSG gearboxes

A double clutch is needed to transfer torque to two rows of gears. The seven-speed equipment contains two friction clutches. In the six-speed version of the box, the clutch is complemented by a drive disk connected to the flywheel and two friction clutches connected to the gear rows via the main hub. In addition, the seven-speed and six-speed DSG models differ from each other in the type of clutch. The seven-speed uses a dry clutch, complemented by an electric pump. This box design reduces oil consumption and increases engine efficiency. The six-speed DSG uses a wet clutch. It requires a large amount of oil, but this operating principle can significantly increase the service life of the equipment.

Each row of gears in the transmission is a primary and secondary row, equipped with gear blocks. During their operation, the second row controls even gears, and the first row controls odd and reverse gears. The input shaft in the second row is a hollow device placed on a similar shaft in the first row. In this case, both primary shafts are placed coaxially.

The gears of the primary and secondary shafts also have different operating principles. Those of them that are on the primary shafts are rigidly connected to the shaft itself. In contrast, the gears on the secondary shafts rotate freely, and between them there are synchronizers that engage the desired gear. In addition, the DSG gearbox is equipped with a reverse gear on the intermediate shaft. This device is necessary for reverse movement. The secondary shafts also contain drive gears, which are responsible for the final drive.

Gear shifting and clutch control are controlled by an advanced control system. It consists of:

1. An electro-hydraulic unit responsible for the operation of the hydraulic control circuit. This block consists of solenoid valves, a multiplexer, distributor spools and pressure control valves. Solenoid valves are designed to change gears. The distributor spools are controlled by a special selector lever. Pressure control valves are necessary for the operation of friction clutches. And the multiplexer controls the gear shift hydraulic cylinders (8 cylinders in total) using electromagnetic valves. Some of the hydraulic cylinders operate in the initial position of the multiplexer, and the other part - in its working position. The same solenoid valves are used during this process.
2. An electronic control unit that ensures the system operates according to sensor signals.
3. Input sensors that control the speed at the output and input of the DSG. Sensors also monitor oil temperature and pressure, and the location of the gear forks.

Video about DSG

Pros and cons of DSG

Based on the characteristics discussed above, we can highlight the pros and cons of the DSG gearbox.

Its advantages include:

• no loss of engine power and its efficiency;
• increased acceleration speed;
• balanced fuel use (a car equipped with a DSG uses fuel 10% more efficiently than a car with a manual or idle automatic transmission gear);
• function of shifting gears in manual and automatic modes (not even every automatic transmission has this option).

Among the disadvantages of this gearbox are:

• high cost of the car (compared to cars equipped with conventional gearboxes);
• complexity of the design, which has a negative impact on the repair of the gearbox (with serious breakdowns you will have to pay a large sum of money for new box gears, since the old one cannot be repaired);
• negative impact on the control system of frequent temperature changes (such changes cannot be avoided when using DSG, so the gearbox fails faster than a mechanical or automatic one);
• the impossibility of repairing the control system and the need for new costs to replace it;
• excessive overheating of the preselector.

These advantages have allowed DSG to become the most popular gearbox for last years. Therefore, many were equipped with it cars. For example, Audi Q5 and R8, SEAT Ibiza, León and Altea, Škoda Yeti and Octavia, Volkswagen Passat CC, Tiguan and Caddy, as well as many other cars from famous world manufacturers.

It is also worth highlighting the disadvantages that are characteristic only of six-speed or only seven-speed gearboxes. For example, a seven-speed DSG breaks down faster than a six-speed. This is due to the peculiarities of the dry type clutch. In addition, in vehicles equipped with a seven-speed transmission, a jerk may be observed during the transition from first to second gear. However, this drawback is not common to all DSGs and is very rare.

Despite all the shortcomings, the DSG is much more convenient than any of its predecessors. It makes driving easier and improves its technical characteristics. Therefore, feel free to buy a car with this gearbox and don’t think about possible problems. With such modern device you can determine your riding style and lock it in with the selector. By doing this, you will save yourself from further contact with the transmission. But do not forget to monitor the correctness of its operation and immediately contact a car service if you detect twitching, noise or other signs of equipment failure.

The automotive industry is developing at an accelerated pace. Every year more and more new technologies appear. Just 20 years ago, an automatic transmission was a curiosity for many Russian car enthusiasts. Today, the list of available transmissions has expanded. If speak about German cars, then they can often be found with DSG 7. Reviews about it, the design and features of this transmission are further in our article.

Characteristic

So what is this box? It is a robotic transmission produced by the Volkswagen-Audi concern. Initially, this box was supposed to have six speeds. However, three years later, a 7-speed DSG gearbox was born. Owner reviews about it were also contradictory. Many people complained about common problems(we'll look at them a little later). The main goal of the creation is to obtain a gearbox that would ensure gear shifting without interrupting the power flow. This is the key DSG feature, which distinguishes it from other robotic gearboxes. At the same time, a car with DSG has better acceleration dynamics and lower fuel consumption.

To ensure continuous transmission of torque from the internal combustion engine to the wheels, German engineers used two clutches and two rows of gears. If speak about technical specifications, DSG 7 is designed for torque up to 250 Nm. The operating pressure of the hydraulic accumulator is from 50 to 75 bar. The volume of oil to be filled is 1.7 liters.

Device

The box design includes:

• Main gear.
• Dual mass flywheel.
• Double clutch.
• Two rows of gears.
• Differential.
• Control system.

Principle of operation

The clutch drive disc, which rotates the engine, is located between two driven discs that are connected to the gearbox. One of them is connected to the gears and shaft of the odd numbered number of gears (first, third, fifth, seventh), and the second is connected to the shaft of the even numbered ones (second, fourth and sixth, respectively). When the car starts moving, only the odd numbered disc is pressed against the drive disc. So the car starts in first gear. As the speed increases, the odd row is disconnected from the drive disk and the even row is instantly attached. When the latter is running, third gear will already be selected on the odd one. Due to this, switching occurs instantly. That is, the operating principle is to sequentially engage the gears of both rows.

Where is it used?

Since the seven-speed gearbox can withstand small torque, it is used on B and C-class cars, as well as on some cars from the D-segment. More specifically, such a transmission is used on cars:

• "Volkswagen".
• "Seat".
• "Skoda".

These are mainly cars with a small engine capacity - up to 1.8 liters. More powerful engines are equipped with a “wet” six-speed DSG.

DSG 7 malfunctions and reviews

Now let's look at the problems associated with this. One of the common malfunctions concerns the gear shift fork. This element moves through a ball bearing bushing. It cannot withstand the loads placed on it, since switching occurs quickly and harshly. If the bushing is damaged, its inner plate begins to float in the box. This causes damage to the gears. Due to metal debris, the Hall sensor, thanks to which the mechatronic control system operates, becomes clogged. Due to destruction, balls may also fall out. Sometimes the box grinds them too. It can no longer be restored.

The DSG 7 design has two forks. Many people believe that only the first and second gear forks can break. But the sixth and rear fork fails no less often. The bearing design is identical here. After 2013, German engineers revised the design of these elements. On the new boxes, the bushings became solid, without a ball bearing. What do reviews say about DSG 7 Volkswagen? With the new bushing, the box has really become more reliable. But buying used cars before 2013 is still dangerous.

Otherwise, mechanical failures are associated with oil contamination due to broken rods. You need to ensure the cleanliness of the liquid. Otherwise, metal dust contained in the oil may cause:

• Chipping of gears.
• Breakage of the differential (at increased load, the satellites are welded to the axle).
• Overheating of the bearings and complete destruction of the seventh gear.

Other problems occur due to insufficient oil level or due to improper assembly (or adjustment of the transmission) after it has been repaired.

Clutch

Almost every owner has encountered this problem. As owner reviews note, the 7-speed DSG gearbox has wear on the flywheel. It wears out due to torsional vibrations during slipping and sudden starts. Also, reviews of the DSG 7 box say that the transmission does not like overheating. The clutch block must be clean.

The slightest dirt negatively affects the performance of DSG 7 on the Volkswagen Passat. Reviews note that the cost of replacing the clutch assembly is very high. The price of this operation is from 50 to 80 thousand rubles, which is comparable to the overhaul of any machine. And this despite the fact that the clutch has a short resource. As reviews note, the Skoda DSG 7 should be serviced every 50 thousand kilometers. In 2012, engineers installed a shield on the hole for the release rods. This made it possible to reduce crankcase contamination and wear of clutch discs. We also note that the transmission needs to adjust the working clearance of the discs. As the reviews state, the Skoda Octavia with DSG 7 should only be configured and serviced by a specialized service center. You should not do any work yourself.

Very often, the resource is reduced due to the vehicle driving through traffic jams and over rough terrain. But as reviews say, the Skoda DSG 7 box does not need to switch to neutral. Both disks rotate freely from each other. Therefore, by moving the selector to neutral, you do not in any way reduce the load on the clutch assembly and the mechatronics.

About the resource

As owner reviews note, DSG 7 has a short service life. The resource is about 150 thousand kilometers. Then even bigger problems begin with the box. By the way, even on the new DSG 7, owner reviews noticed problems. The box jerks and selects the wrong speed to change gears.

Mechatronics breakdowns

We continue to study reviews about DSG 7. This transmission also has faults regarding the electro-hydraulic control unit. Moreover, these breakdowns can also affect the mechanical part. As reviews note, DSG 7 has the following malfunctions. This:

• Damage to the electronic board or its sensors.
• Failure of the pressure accumulator.
• Damage to the pump electric motor and control solenoids.
• Problems with the mechatronics housing or accumulator glass. Owners are faced with the phenomenon of channel cracks.
• Loss of sealing of the box and various leaks.

Many had to completely replace the mechatronics of the robotic transmission due to the complexity of the design and lack of spare parts. The situation became more complicated in 2015. So, the mechatronics began to flash and when installed on another car simply did not work. Because of this, it was impossible to purchase any unit from disassembly. I had to shell out money for a new one.

Electrical faults

Among the most minor reviews, blown fuses in the power circuit are noted. Also, the board conductors burn out on the DSG, damaging its body. Due to problems with the pump, the car simply refuses to go further. Another problem is a burnt-out pump winding. The board is ceramic and is very susceptible to temperature changes, vibrations and overheating. However, this unit can still be repaired. But this requires special equipment.

How to save a resource?

• You should not slip when starting.
• In case of a long stop, you should switch to neutral mode.
• It is not recommended to move quickly through the rows at speeds up to 50 kilometers per hour.
• Change on time transmission oil(every 40 thousand kilometers).

Let's sum it up

So, we found out what the seven-speed DSG robotic gearbox is. Among its positive aspects it is worth noting:

• Speed ​​of gear shifting. Gears are engaged almost instantly and even faster than with a manual transmission.
• High acceleration dynamics. This is achieved through the continuous supply of torque to the wheels of the car.
• Uniform acceleration. In the case of a conventional manual or automatic transmission, characteristic jerks are observed during dynamic acceleration and an attempt to change gear.
• Opportunity to work in manual mode. This function allows the driver to independently choose his driving style.

But there are also a number of disadvantages due to which many car enthusiasts refuse to purchase a car with a DSG in favor of a conventional automatic or manual transmission:

• A small resource. Even with proper maintenance, such a gearbox runs on average 150 thousand kilometers.
• Unreliability. We have listed the common breakdowns that occur with the seven-speed DSG robotic gearbox earlier.
• Low liquidity in the market. Many people know about DSG malfunctions, and therefore it will be difficult to sell such a car.
• Difficulty of repair. It is not possible to carry out any repairs yourself. This work requires specialized equipment, knowledge and tools.
• Complex and expensive, special oil is used, which is more expensive than a regular “transmission”. Also, replacement can only be performed at a service center. And this is additional money expenditure.
• High price car. Cars with DSG are an order of magnitude more expensive than those with a conventional automatic transmission.

Is it worth buying a car with a seven-speed robotic gearbox? There is no clear answer to this question. Experts note that it is advisable to take such a car if it is new and under warranty. Then you can really appreciate the benefits of using DSG without any investment. But if you decide to choose a used German car, you should refuse to buy a car with DSG. In most cases, the warranty on this box is expired and the future owner will have to deal with the malfunctions on his own. And since the box is very complex, you need to look for specialized services. This significantly affects the cost of maintaining a car. The costs of repairing the box turn out to be unreasonably high. Therefore on secondary market preference should be given to mechanics or a classic six-speed automatic transmission.

A 6- or 7-speed DSG gearbox is one of the newest types of transmission. Like other gearboxes, this type has its advantages and disadvantages. Read below about the advantages and disadvantages, as well as the design and operating principle of a robotic gearbox.

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Design and technical details of DSG boxes

The DSG automatic transmission is a unit equipped with a double clutch. Such gearboxes are installed on cars produced in 2013, 2014, 2015, 2016 by VAG. The driver of the car selects the speed, and the transmission control module automatically controls the clutch and transmits the appropriate commands to shift gears. The main feature of robotic gearboxes is the presence of two clutches in the design, as well as five shafts. Thanks to this, car manufacturers were able to achieve maximum speed with a short acceleration time, as with a conventional “mechanics”.

The design of the DSG gearbox includes the following elements:

• two rows of gears;
• double clutch;
• crankcase device;
• control module for receiving, processing and transmitting signals;
• differential;
• smooth transmission.

DSG gearbox device

Kinds

There are two types of robotic transmissions:

1. Six-speed. These cars use a double wet clutch. It always works in oil, which is used to lubricate the rubbing elements and cool the discs. This helps to increase the service life of the transmission unit. This gearbox is not the latest model from robotic boxes Volkswagen, however, is considered one of the most powerful. The torque varies around 350 Nm.
2. Seven-speed. Such gearboxes use a “dry” clutch, which is why the unit requires three times less lubricant. Unlike six-speed gearboxes, which used hydraulically driven oil pumps, seven-speed gearboxes are equipped with electrical devices. This reduces energy costs and increases fuel efficiency power unit. But clutch life is shorter. Seven-speed transmissions began to be installed on cars three years after the release of DSG 6 and they are intended for more budget car models. The total weight of the box varies around 70 kg. The gearbox torque is no more than 250 nm. The main feature of this type of transmission is that it is equipped with two friction clutches that do not operate in an oil bath. Thanks to this, engineers were able to achieve the highest coefficient useful action unit.

Principle of operation

The main catalyst that ensures the transmission of torque to both rows of gears is the double clutch of the automatic transmission. Thanks to it, the master disk starts. This element is connected to the friction clutches, as well as the flywheel, through a special hub with another built-in flywheel. Thanks to the hub, both rows of gears are combined. The first one works only with odd speeds and reverse gear, and the second one works exclusively with even ones. Each row of the transmission unit functions in conjunction, consisting of two shafts with gears.

The main component of any unit is the control module, consisting of:

• controllers designed to collect information from various systems vehicle;
• electronic component used to control the unit using a computer utility;
• hydraulic device;
• mechanisms and components designed to execute commands issued by the control module.

The central processor is installed directly in the gearbox housing, that is, in the transmission housing. The hydraulic device, as well as electronic components, are located in one unit - mechatronics. Controllers, to which impulses are transmitted from other machine systems, are installed in the same block. Input regulators are used to read information about how rotation occurs at the output and input of the transmission unit. Thanks to them, they diagnose the temperature of the lubricant, the pressure in the system, as well as the correct location of the gearbox forks. The control module receives data from the controllers, as a result of which the system launches one of the cycles stored in the memory of the central processor program.

Hydraulic or electrical device used to adjust the transmission circuit.

The main components of this system:

• control and solenoid valves, the former are used to control pressure levels;
• distribution spools;
• multiplexer.

When the driver moves the gear lever, the switchgears begin to operate. The speed switching procedure is carried out as a result of the action of solenoid valves. The process of adjusting friction clutches is carried out under the influence of pressure valves. These components are considered executing. The multiplexer is installed in the gearbox to control the hydraulic cylinders. There are eight of them in total, but during operation of the unit only four valves operate simultaneously. When the driver switches the gearshift lever positions, the multiplexer operates in different modes, resulting in different cylinders functioning. But there are always four of them.

User Yaroslav Efremov in his video talked about the main malfunctions characteristic of robotic boxes.

Basic faults

In operation even the most reliable automatic transmission Breakdowns and errors may occur that lead to the repair of units.

Below is a list of problems that, according to reviews from owners of cars with DSG, occur most often:

1. Failure of the clutch due to rapid wear. The main symptom of this problem is the periodic loss of reverse speed, and when the driver engages the gears of an even row, the car begins to move with jerks and jerks. Since the box is controlled by a central processor, the unit can automatically go into emergency mode. In this case, one of the speed rows will not be turned on. An error will remain in the memory of the central processor, which will allow you to identify the malfunction using the computer diagnostics. To correct the breakdown, you will need to replace the friction clutch assembly or individual disks of this assembly. Usually a shift individual elements is relevant if the vehicle’s mileage is no more than 150 thousand km. When performing repair work, adjustment is necessary using diagnostic stand. Also, the clutch of the box must be adapted to the car while driving.
2. Failure of mechatronics solenoids due to wear. We are talking about elements designed to regulate pressure. Failure of the solenoids causes jerking when changing gears. The unit can continue to operate in this mode, since the central processor does not see this problem and does not leave the error in its memory. To get rid of the malfunction, you will need to replace the solenoids or install a new mechatronics on the gearbox.
3. The mechatronics control module began to work intermittently. Such problems clearly manifest themselves during a cold start of the car engine. The transmission unit begins to operate in emergency mode, but after restarting the internal combustion engine continues to function normally. The main feature of this problem is that the gearbox may go into emergency mode unpredictably, for no apparent reason, when the car is moving. The control module writes the corresponding errors to memory. To solve the problem, it is necessary to change the mechatronics or central processor. In some cases, the control module must be repaired.
4. Failure of bearing elements, the mechanical component of the unit on the input shaft as a result of wear. The system differential may also break. The main “symptom” of this problem is the appearance of noise from the gearbox while driving. When the driver presses the gas pedal and the crankshaft speed increases, the sounds become louder. If the differential has failed, the noise will also appear when entering a turn. Sometimes it appears when sharp acceleration or braking the car. Such problems can have serious consequences for the transmission unit. If they are not corrected in time, other components of the gearbox may fail. As a result of a breakdown, wear products in the form of metal dust will clog the mechatronics. The device may not work correctly and may break down over time. In this case, clutch wear will be faster. As a result, the malfunction will lead to the need to perform overhaul Checkpoint. Please note that it is impossible to find new bearings, differentials and shafts on sale; DSG manufacturers do not produce such spare parts. Therefore, if replacement is necessary, you will have to look for parts on the secondary market.
5. Another problem is the failure of the dual-mass flywheel due to wear. The first sign of a problem is the appearance of noise and clanging when the engine is running at idle speed. Sounds also appear when the power unit starts and stops. To get rid of the problem, the flywheel is changed.

1. Failed robotic gearbox clutches 2. Worn transmission bearing parts

Troubleshooting

In Audi, Seat and other VAG cars, almost all faults are mechanical in nature. If the moving components and units of the unit wear out, they must be replaced. Please note that elements wear out much faster when the driver sharply increases speed and brakes just as sharply, or often sits idle in traffic jams. Repair work problems related to the central processor are best left to specialists. If you make mistakes when installing the control module or flash it incorrectly, this will lead to serious problems in the operation of the unit.

Oil change intervals and cost

The lubricant change interval depends on the manufacturer, as well as the make of the car. In DSG 7 0AM and 0CW gearboxes there is no need to change the oil, since it is filled for the entire service life of the machine. In all other transmission units lubricant Filled at 60 thousand km.

It is necessary to change the oil in the following cases:

1. If problems arise in the operation of the transmission unit. The box began to kick and push when changing gears, but all its component components and mechanisms were intact. Such problems indicate the use of low-quality transmission fluid.
2. If the oil turns black and deposits appear in it in the form of metal shavings and other wear products. It is necessary to identify the malfunction and remove it, and then start flushing the unit and replacing the lubricant. Over time, wear products will clog the channels of the system, which will lead to its inoperability.

Operating rules

To prevent malfunctions and ensure the reliability of the transmission, you need to know how to use it:

1. When you switch the main gearbox modes with the lever, the brake pedal should be pressed all the way. The design of the robotic transmission is such that if the driver presses the brake weakly, the clutch discs will not be able to open completely, which leads to their rapid wear.
2. Try to use neutral speed as little as possible. If you are stuck in a traffic jam or plan to stop for no longer than one minute, then it is better to coast. In this case, on the box itself, the selector should be moved to position S. This will reduce the likelihood of wear on the clutch unit and prevent damage to important structural components of the unit.
3. Vehicles equipped with robotic gearboxes cannot be used for towing. The transmission is designed for a certain vehicle weight, so it is not allowed to tow other vehicles or use a trailer on such vehicles. An exception may be SUVs. Their mass is quite large, so the load on the box will not be so critical.
4. Never skid your car; we are talking about a sudden start of movement with wheels slipping.
5. If you move the gear selector to the parking position, you do not need to release the brake pedal. The handbrake should be raised to prevent the limiter from failing if the car starts to roll back.
6. All positions of the gearbox selector must be engaged smoothly, observing a second delay. Please note that electronics need a certain time to adjust to a particular mode.

These rules are similar to controlling a traditional machine, but in the case of “robots” there are some peculiarities. Such transmissions, unlike classic automatic transmissions, can transfer the car from position D to driving mode in reverse without pause at neutral speed. On cars with an automatic transmission, you can drive with slippage. This is harmful for the transmission unit as a whole, but not as critical as for robotic gearboxes.

If you get into a snowdrift or are stuck in the mud and you cannot get out of the obstacle under your own power, then when pulling the car out of the snowdrift, the gearbox selector should be switched to neutral gear. When towing a vehicle, remember that the speed of movement should be low. There is also a certain distance that a vehicle can be towed. This data is usually indicated on the front pillar of the car.

User JoRick Revazov published the video. in which he talked about the mistakes of car owners of cars with DSG.

Pros and cons of "robots"

Let's consider the advantages of robotic transmissions:

1. In such gearboxes, gears change almost instantly. Thanks to this, the driver does not lose precious seconds when overtaking or performing other maneuvers on the highway.
2. All manufacturers of cars equipped with robotic gearboxes claim fuel savings. This is a debatable advantage. Perhaps such cars actually consume less fuel, but only compared to automatic transmissions.
3. DSG boxes do not take power from the power unit like manual transmissions.
4. Manual control of the unit will allow the driver to independently choose the mode in which it is better to move.

The main disadvantages of DSG:

1. High cost of repairs. If a part or mechanism on the “robot” fails, you will have to pay a lot of money for repairs. It may be difficult to find spare parts.
2. The mechanical component in such units is not reliable. Even if we are talking about new cars.
3. The process of changing transmission fluid is complex. Change the lubricant in garage conditions problematic because design features unit. If you turn to a service station for help, you will have to pay a hefty sum for a replacement.
4. Robotic transmissions have a negative attitude towards an aggressive style of movement. The components and elements of such gearboxes wear out faster during sudden starts and braking.
5. The cost of vehicles with a robotic transmission is higher than those with automatic or manual transmission.

The DSG transmission is a family of preselective gearboxes installed on Volkswagen AG vehicles.
The first DSG went into production in 2003, beginning to be serially installed on many models.
Since then, robotic gearboxes have been changed several times, and new modifications have appeared.

“ They differ from each other in the clutch design, layout relative to the engine, and are also designed to work in tandem with engines having different volumes, torque and type of fuel.

Today there are the following types of DSG:

• DSG6-02E/0D9 (DQ250)- the only version of the DSG with six stages.
  Equipped with a “wet” clutch, designed for front- and all-wheel drive vehicles, with a maximum torque of up to 350 Nm, and a volume of 1.4 - 3.2 liters;
• DSG7-0AM/0CW (DQ200) - the first generation of a seven-speed preselective.
  Dry type clutches. Designed for use with low-power internal combustion engines. Scope of application - front-wheel drive cars 1.2 -1.8 l, up to 250 Nm;
• DSG7-0BT/0BH (DQ500)- 7 steps, “wet” clutch.
  Installed on powerful models with front or all-wheel drive, and a transverse engine arrangement. Adapted for transmitting high torque (up to 600 Nm);

DSG7-0B5 / 0CJ / 0CL / 0CK (DL501 / DL382) - also have seven gears and a “wet” clutch, but were developed specifically for cars with a longitudinal engine.

To find out what type of gearbox is installed on your car, just connect the diagnostic tool and read the identification data, or check by VIN code in the corresponding catalog.