Modern cars are fundamentally different from those that were presented 20-30 years ago. Moreover, the changes affected everything - from the engine to the suspension. The gearbox was no exception . If earlier the choice was between mechanics and automatic, now the DSG has appeared in the list. This is a robotic box with a different number of steps. But, despite its adaptability, many owners speak negatively about it. What is a DSG robotic transmission? Owner reviews, problems and features - later in the article.
Characteristic
So what is this box? DSG is a robotic gearbox, which is available in several versions:
- DQ250. It features a wet clutch. The number of transmissions is 6. This is the first robot box developed by Volkswagen-Audi Concern together with Borg Warner in 2003. The design uses double clutch discs that work in an oil bath. The transmission is capable of transmitting torque up to 350 Nm and at the same time save fuel. As noted in the reviews, “Skoda” with a DSG spends less fuel than on mechanics. Basically, such a transmission is used on powerful engines. These are two-liter turbocharged units TSI and TDI (gasoline and diesel, respectively).
- DQ200. This is a seven-speed robotic box, which was born in 2008. It features a "dry" clutch. However, the hydraulic pump does not work continuously. An electric motor is used here, which starts the pump according to a specific requirement. The maximum torque that this box is able to withstand is 250 Nm. Since this transmission can withstand lower loads, it is mainly placed on small and middle class cars with 1.4 and 1.6 liter engines (one of these cars is Volkswagen Golf). This box is characterized by faster operation and economy. However, the high speed of work negatively reflected on the comfort and reliability of the DSG 7. In the reviews, drivers note frequent breakdowns of the seven-speed “robot”.
S-Tronik
Among other modifications, it is worth highlighting the S-Tronic box, developed in the same year 2008 for Audi cars with a longitudinal arrangement of ICE. This box had a wet clutch and 7 speeds. The transmission can withstand up to 600 Nm of torque (but as noted in the reviews, the DSG 7 after 2010 could only withstand 500 Nm).
What are the advantages of the box?
The main plus of the robotic box in its speed. Since the transmission has two clutches, gear changes occur instantly (even faster than on the mechanics). When the car pulls off in first gear, the second is already engaged. The box contains not only two clutches, but also two rows of shafts. Torque is continuously transmitted to the wheels, which is positively displayed on the dynamics of acceleration. Moreover, such cars are more economical than with manual transmission.
However, all the advantages end there. What problems happen robotic boxes of the above modifications? They are discussed further.
Mechanical part
On the mechanical side of the DSG box, reviews indicate a malfunction of the gear forks. They operate by means of a ball bearing sleeve. This design does not withstand heavy loads.
After damage to the sleeve, the plate of the element begins to “float” in the box. Thus, gear damage occurs. This entails the appearance of metal workings that work like an abrasive. In rare cases, the balls themselves are destroyed. If they get into the box, the owner may get a major overhaul.
Some believe that only the fork of the first and second gears can be damaged. However, problems with a sixth (rear) speed fork are no less common. After all, the design of the bearings here is the same. But it must be said that after 2013, other forks with an integral design began to be put on the DSG. As noted in the reviews, there are no problems with the DSG (the statement concerns forks).
Other breakdowns usually occur due to oil contamination, which occurs when stocks break. The result is:
- Chipping gears.
- Differential damage.
- Seventh gear destruction (on dry-clutch DSG).
The second breakdown also occurs due to the unsuccessful design of the satellites, which are welded to the axis under increased load.
Clutch
This node is quite complex. Two clutches and a two-mass flywheel are used in the DSG robotic box. The latter suffers wear during large torsional vibrations. This is due to abrupt starts and slippage of the clutch disc.
As noted in the reviews, DSG boxes do not like dirt, especially in the clutch unit. In 2012, the design of this unit was finalized. So, the manufacturer began to install a shield on the hole for the squeeze rods. This significantly reduced the pollution (and, accordingly, the wear) of the clutch housing. Also note that the adjustment of the working clearance of the clutch is required to be done in a car service. This operation requires high precision.
Exploitation
What do they say about Volkswagen 1.4 TSI with DSG in reviews? The DSG box does not like frequent traffic jams. In view of this, the transmission unit is significantly loaded. Therefore, the manufacturer recommends moving the selector to the “neutral” position for prolonged downtime (more than 30 seconds). The resource of the clutch disc is about 50-80 thousand kilometers. However, there were cases when the disk "ended" at 30 thousand kilometers. On a run of up to 100 thousand, these problems were eliminated under warranty. However, many owners were unhappy that they had to wait a long time for a new part.
Problems with mechatronics on 1.4 cars with DSG
The reviews note that the seven-speed dry clutch gearbox has frequent problems with mechatronics. This is an electro-hydraulic unit that controls the operation of the transmission. Problems with mechatronics can affect the mechanical part of the gearbox. Among the frequent DSG malfunctions in the reviews, note:
- Pump motor
- Transmission solenoids (solenoid valves).
- Pressure accumulator.
- Sensors of the electronic board.
- Damage to the mechatronics housing and pressure accumulator cup.
- Various leaks and loss of tightness at joints.
In the reviews, it is noted that the mechatronics unit is poorly assembled, which is why frequent malfunctions arose. The unit itself is not repairable. I only had to change it. The picture worsened in 2015, when the Volkswagen-Audi concern began to install “stitched” for a specific auto block. If earlier it was possible to replace mechatronics with a purchased one from disassembly, now you can only contact an authorized dealer for help (of course, not for free).
Electronics
Owners also encountered electrical problems. They are connected to the hydraulic unit. Among the common mistakes that occur during diagnosis, it is worth noting:
These codes are associated with:
- Damaged circuit board conductors.
- Failure of the electric pump mechatronics DSG.
The problem is compounded by the fact that the conductors literally burn out and damage the case of the board itself. As a result, the car simply refuses to drive on. As for the second problem, it happens due to the burned-out winding of the electric pump.
I must say that our experts have learned to repair damaged boards. So, the masters solder the power tires, and the pump motor is changed to a new one. The cost of restoration does not exceed five thousand rubles.
Other board issues
There are other problems that are related to the board. In this case, error code 05636 P1604 appears.
In this case, the code indicates that the control module has been damaged. As noted in the reviews, the DSG ceramic board is very afraid of temperature extremes and increased vibrations, which are not uncommon with our roads. But the electronic unit has a ceramic substrate, so it can be restored.
Sometimes sensors fail. They can be replaced with new ones. Solenoid valves (solenoids) also fail. There are eight on the DSG box. All of them are combined in two blocks. Some make an attempt to flush, but this does not always save. The fact is that the winding of the solenoids loses the necessary resistance. In such a situation, only a replacement saves. The cost of a set of two blocks (restored) is 5-5.5 thousand rubles, excluding installation work.
As for the control board of the mechatronics DSG (serial number - 927769D), it costs about 40 thousand rubles (excluding the cost of replacement). This includes:
- Electronic control unit.
- Connectors
- Sensors
- Conductors.
To replace the control board mechatronics DSG resorted to if partial repair is not possible. As for the repair price of mechatronics, it is about 35 thousand rubles. As noted in the reviews, on DSG 6 it makes sense to restore the block. The resource of such a box is no less.
What else?
Pitfalls do not end there. The reviews say that one can expect troubles from the side of the main aluminum board-block body. The hydraulic accumulator breaks out of the block with a damaged thread; often, in addition, the housing cover bends and fluid escapes. The latter flows in the region of the “glass” of the accumulator. This crack can be welded, but the work is complicated and requires cavity milling. In most cases, the case itself changes. Its price is about $ 150.
Modernization
Of course, German engineers did not stand still and constantly improved the design of the box. After all, there were a lot of calls to an authorized dealer. So, in 2013, the modernized DSG began to be installed on Volkswagen, Audi and Skoda cars. In the reviews, it is noted that the control board appeared in the design more powerful and resistant to temperature and increasing currents. The mechatronics case also became durable. But the design of the accumulator, as noted in the reviews, has not changed. The same goes for the pump electric motor. The manufacturer also assures that the mechatronics oil has been replaced by a less chemically active one. This allows you to increase the life of the plastic control board and the solenoids themselves.
Thus, there are almost no problems with the electrical part. But mechanical faults have a place to be. Fortunately, the cost of restoration can be lower, thanks to a good selection of parts from disassembly.
DSG life
How many serves on TSI DSG engines? The reviews say that the box has a small resource, if we take into comparison the classic Aisin submachine gun, which also equipped the Volkswagen-Audi concern. So, it is clutch that gives the most problems. The figure is different for everyone. In some, it becomes worthless after 20 thousand, in others on 100 thousand.
I must say that the guarantee for DSG is 5 years or 150 thousand kilometers, so the dealer does all work with a two-mass flywheel, clutch, mechatronics and other components. The resource of the box itself is about 180 thousand kilometers.
To make the box last as long as possible, the manufacturer is recommended to change the oil every 40 thousand kilometers. And this applies to both dry and wet DSG. By the way, they use different oils.
And one more thing - the filling volume on dry DSG is not 1.7 (as prescribed by the plant), but 2.1 liters. Also, in order to extend the life of the box, some do the firmware of the block. Firmware with a more gentle operating mode is “poured” onto the computer. This reduces dynamics, but increases the resource box.
The most resourceful was the six-speed wet clutch DSG. It serves about 200 thousand kilometers. But during operation, owners may encounter various problems, which were described above.
To summarize
So, we found out what a robotic DSG box is. As you can see, she has a lot of negative reviews and problems. But in most cases, this applies to dry DSG, released before 2013. Should I buy a car with this box? Many owners recommend giving preference to simple mechanics, or the Aisin machine. They are more reliable in operation. But if you plan to buy a new car, you can take a chance and take the DSG. After all, with such a box, the car has lower fuel consumption and better dynamics. However, it should be remembered that with the end of the warranty all problems will fall on the shoulders of the owner. And to restore the box will be expensive in case of serious damage. And in the secondary market, such cars are not particularly relevant. The stereotype of the unreliability of the DSG has taken root so much that even five-year-old cars (after 2013) with the DSG are cheaper than the same, but on the mechanics.