This corner is dedicated to the VAG DSG Gearbox and the Mechatronic units.
The DSG mechatronic unit is a critical component in a Direct Shift
Gearbox (DSG). It serves as the brain of the transmission, controlling
the gear shifts, clutch engagement, and various hydraulic functions. It
combines both mechanical and electronic elements to facilitate smooth
and rapid gear changes. The mechatronic unit receives input from
sensors, processes data, and uses solenoids to actuate clutches and
shift gears seamlessly. Its sophisticated design and precise operation
are essential for the overall efficiency and performance of the DSG
transmission system.
Before you continue I would recommend some reading :
Dual clutch gearbox 02E
Electrical Connections - Passat
It seems that most affected cars are the VW Passat , VW Touran and the
VW Golf produced between 2003 and 2009. I have only seen a few Skoda and
a few Seat. Maybe because they are not so abused :) If you consider my information useful please
click some of my adds to keep this site up and runing.
Currently, the world of transmission is dominated in Europe by
manual gearboxes and in the USA and
Japan by automatic gearboxes. Both types of gearboxes have specific
advantages and disadvantages.
The advantages of a manual gearbox are, for example,
• high degree of efficiency
• robust and sporty characteristic.
The advantages of an automatic gearbox are, for example,
• a high level of comfort, above all in gear changes, as there is no
interruption in tractive power.
This formed the framework for Volkswagen to combine both
transmission concepts into one completely
new gearbox generation: the direct shift gearbox.
Thanks to the double multi-plate clutch design and
different automatic gear selection programmes, it is
well capable of meeting the high demands in comfort from drivers who
favour automatic gearboxes.
Furthermore, with direct selection and lightning fast, jolt-free
gear changes, it also offers a high level of
driving enjoyment to drivers who favour manual gearboxes.
In both cases, fuel consumption is at a par with economical vehicles
fitted with manual gearboxes.
The mechatronic unit in a Direct Shift Gearbox (DSG) is a complex
component that can experience various issues over time. Some common
problems with DSG mechatronic units include:
Faulty Solenoids: The mechatronic unit
relies on solenoids to control hydraulic pressure for gear
changes and clutch engagement. Malfunctioning solenoids can lead
to erratic shifting, hesitation, or complete transmission
failure.
Electrical Problems: As the mechatronic unit
is heavily reliant on electronic controls, issues with wiring,
connectors, or circuitry can cause communication errors and
result in improper gear selection or unexpected behavior.
Fluid Contamination: Contaminated or
degraded transmission fluid can clog the mechatronic unit's
small passages and affect its performance. Regular fluid
maintenance is crucial to prevent such problems.
Clutch Wear Adaptation: DSG mechatronic
units have adaptive learning capabilities to adjust clutch
engagement based on driving habits. However, over time, this
adaptation process may cause the clutch to engage improperly,
leading to slipping or jerky shifts.
Overheating: DSG mechatronic units generate
heat during operation, and excessive heat can cause damage to
internal components and lead to issues like solenoid failures or
electronic component malfunctions.
Software Glitches: Software bugs or glitches
can affect the mechatronic unit's programming, causing shifting
irregularities, unexpected behavior, or even triggering warning
lights on the dashboard.
Mechanical Wear: The mechanical components
within the mechatronic unit, such as gears or actuators, can
experience wear and tear over time, leading to reduced
efficiency and reliability.
Lack of Maintenance: Neglecting regular
transmission fluid changes or software updates can exacerbate
potential issues and reduce the mechatronic unit's lifespan.
Manufacturing Defects: In some cases,
mechatronic units may have manufacturing defects that lead to
premature failures or performance problems.
Most of the valves can be refurbished but until now
I have never seen anyone being able to refurbish the Pressure
Control N215 or Pressure Control N216.
Some of the most common symptoms of a Mechatronic
Failure are :
Flashing PRNDS in the Dash and the gearbox will
switch to neutral.
Hard engaging of the 1st gear (slams into the
first gear) from a stand still point or in Reverse. This can sometimes
also be caused by a decallibration of the clutches so you might
be able to "save the day" by performing a recalibration
with a VCDS cable. Procedure can be found on
Ross Tech website. * If this does not help or only for
SHORT term, your next move is to change the N215 / N216
solenoids.
Hard downshifting from 3 to 2 and 2 to 1st gear
followed by some loud "clunk" noises. * Again, this
can be caused by sticky N215 / N216 , changing them should help. Problem can SOMETIMES be attenuated in software with a
remap
Shaking / juddering feeling while in 2nd gear
and the car pulls up. *
Jerking between gears *
* This problems can be caused by worn
valves. Changing the affected valve might solve your problem
(N215 / N216).
Loss of power between 1300-2000 RPM. Car feels
like dead
If you have any other experiences please let me
know, I will add them.
For whoever needs I can supply electronic parts for
the DQ250 DSG Mechatronic / Mechatronik units.
I have the following :
Pressure Control N215 Valve 1 (N215)
Pressure Control N216 Valve 2 (N216)
Pressure Control N217 Valve 3 (N217)
Pressure Control N218 Valve 4 (N218)
Pressure Control N233 Valve 5 (N233)
Pressure Control N371 Valve 6 (N371)
Circuit boards, solenoids and also some whole Mechatronic
units are available also upon request. Mechatronic Pressure Control Valves are available on request.
This valves are present in ALL VW/Audi group DSG Mechatronic
gearboxes and usually you will be able to read one of this error
codes when one valve goes :
18222 P1814 Pressure Control Valve 1 (N215), Open / Short to Ground
**
18223 P1815 Pressure Control Solenoid 1 (N215), Short to B+ **
18226 P1818 Pressure Control Solenoid 2 (N216), electrical
malfunction **
18227 P1819 Pressure Control Solenoid 2 (N216), Open / Short to
Ground **
18228 P1820 Pressure Control Solenoid 2 (N216), Short to B+ **
N215 / N216 errors appearing on the newer versions of
mechatronic units like 02E927770AL , 02E927770AM , 02E927770AT ,
02E927770AS , 02E927770AQ would probbably be caused by BAD N215 /
N216 solenoids. Try replacing this solenoids before doing
anything else.
** This errors can be caused by insufficient
oil in the gearbox. Please check the level and the quality of oil
first.
18231 P1823 Pressure Control Solenoid 3 (N217), electrical
malfunction
18232 P1824 Pressure Control Solenoid 3 (N217), Open / Short to
Ground
18233 P1825 Pressure Control Solenoid 3 (N217), Short to B+
18236 P1828 Pressure Control Solenoid 4 (N218), electrical
malfunction
18237 P1829 Pressure Control Solenoid 4 (N218), Open / Short to
Ground
18238 P1830 Pressure Control Valve 4 (N218), Short to Plus
18241 P1833 Pressure Control Solenoid 5 (N233), electrical
malfunction
18242 P1834 Pressure Control Solenoid 5 (N233) Open / Short to
Ground
18243 P1835 Pressure Control Solenoid 5 (N233) Short to B+
18246 P1838 Pressure Control Solenoid 6 (N371), electrical
malfunction
18247 P1839 Pressure Control Solenoid 6 (N371) Open / Short to
Ground
18248 P1840 Pressure Control Solenoid 6 (N371) Short to B+
FACTS : If your mechatronic unit
has THIS PART NUMBER 02E927770AJ please
AVOID remapping / tuning your gearbox. It might cause
your unit to brick ! So owners of 02E927770AJ units, make sure this
unit stays with stock software. If you get ANY of this errors
mentioned on your 02E927770AJ this unit is most
certain beyond repair. I have seen very few cases where 02E927770AJ
can be repaired. This units are called EXX units and are produced
between 2008 and 2009 , after that VAG dropped them as being to
unreliable. We have seen also 02E927770AJ
bricking while performing basic settings.
I DO NOT RECOMMEND flushing the DQ250 ...
geabroxes have an internal filter INSIDE the geabox , and
if flushed the gearbox might clog this filter and other problems
might arise from there.
Most of the older Audi TT will ONLY run with
hardware 02E927770AD , so if you own an older Audi
TT and your mechatronic unit is an 02E927770AD , it is most likely
that this car will not run with any other part number than
02E927770AD. SOME versions will accept 02E927770AM , 02E927770AL ,
02E927770AT , 02E927770AS but not all of them.
The following error is most likely caused by
a mechanical problem (most likely worn) clutch but can also be an error on the Mechatronic
unit or wrong software version.
So if you get this errors after replacing your mechatronic unit , make sure the software version on the "new"
mechatronic unit is the correct version for your car.
If you need some of this or you have any problems
with your DSG Gearbox of the Mechatronic unit please drop me an e-mail
at jaxelos @ gmail.com and if I
have time I will try to help.
My time is VERY LIMTED and if I can see you waste my time I will not
answer. When you ask questions please send LOG FILE with ALL the
errors , history of WHAT has been done previously and provide me
AT LEAST VIN number so I know what kind of gearbox you have, I am
not GOD so I can't guess !!!
In order to get a better
overview of your problem please try to DESCRIBE the problem as good
as possible but do no write me a whole novella.
Remember to say "HI" and present
yourself so I know who I am writing
with and please
tell me from where you are!
I will NOT answer e-mails like this :
"I have a problem with my DSG, please help me"
or
"Do you have a file for DSG6 6?"
or similar e-mail. I will try to help the people who really need
the help but please do not waste my time.
If you have a LOG file with the errors of the car please SEND the
log file along with the e-mail.
Send me some details about the car also : Make, model, year, engine
code, gearbox code,VIN number and please try to get the
error
codes... as many details about the problem as possible.
I RECEIVE INSANE HUGE AMOUNTS OF E-MAIL RELATED
TO DSG PROBLEMS LATELY AND I SIMPLY
DO NOT HAVE TIME TO ANSWER EVERYBODY ANYMORE , SORRY !!
WITH MANY PEOPLE I USE DAYS TO TRY AND DIAGNOSE
A PROBLEM AND AT THE END I DO NOT EVEN RECEIVE A "THANKS".
IF YOU THINK MY TIME IS WORTH SOMETHING
AND YOU REALLY NEED MY HELP PLEASE
MAKE A SMALL DONATION TROUGH PAYPAL.
If you want a guaranteed answer and help then please buy a
support ticket here:
I can fix /repair
Mechatronic units including the circuit boards if necessary. Let
me know what the problem is with the unit and I can give you a
quote. !!! I live in DENMARK !!!
BEFORE YOU SEND ME ANY
QUESTIONS regarding problems with your DSG gearbox make sure you
have checked the following:
ALL YOUR ABS Sensors are working in perfect
condition. You can log the signal of all 4 sensors with the VCDS
Tester. or VCP. The most important one here is the REAR wheel sensors.
Make sure your diesel filter is changed and
not filled up with oil.
You changed the DSG oil and filter and you
performed the DSG Adaptation correctly.
You have no other errors on the engine control
management.
Your EGR Valve is in good working condition
and engine runs as it should.
CHECK your VACUUM Pump and be sure there
are NO OIL LEAKS that will reduce the Vacuum necessary for the
perfect working condition of the engine.
Did YOU or someone else made software
modifications to the Mechatronic ? What has been done and when ?
DSG it is pretty strong in terms of mechanics ,
If you want to keep your DSG gearbox in good condition I would
recommend the following :
- Changing oil
before the 60.000km indicated in the book (I recommend 40-45.000km
as the gearbox is very sensitive about oil quality and you can never
drain it all)
- Do not overheat the car and do not push it to its limits when HOT.
- Keep the engine in good working condition (smallest problems can
influence how the gearbox changes and reacts).
- Once in a while check the rear wheel bearings on the rear wheels
(they have the ABS rings built in) and if you feel they are noisy
change them.
- Do not drive with the car in water that can go above your DSG
connector on the gearbox.
- Keep the engine room clean and once in a while (every 2-3 years)
clean all the earth connections in the engine bay.
- Check your fuel filter for oil residues and change it regularly.
(On some engines the vacuum pump tends to leak oil)
- Check the condition of the DMF and if it's noisy or it has play,
change it before it damages the clutches, drive shafts.
- Check Cooling fluid level regularly and if it drops below level
and you can not see where the water goes, check gearbox oil for
contamination. DSG oil coolers tend to break and oil contamination
will occur.
Here is a detailed video on
how to change the Valves / Solenoids on your mechatronic unit.
Thank you in advance.
Here below is one of my old videos while I dismantled and put back
together the DQ250 Mechatronic unit.
Some more videos will come soon. This was a defective unit and I
have made the video just for documentation.
It was a long time ago when I was a noob :)
DQ250 02E927770AQ Units and newer are immobilized units. So if your
unit it is broken , you can not just replace it with another
02E927770AQ unit without making a clone of it where both Flash and
Eeprom are copied over. For now , there is no VIRGIN sollution for
the DQ250 0D9.... for now.
I can also flash new software to existing Mechatronic
units or repair them taking your old units in exchange.
I can also fix the CIRCUIT BOARD and not only the components in the
Mechatronic unit.
The Mechatronic units are intercheangeable
between car brand and model (no matter what your dealer said), they
just need to be re programmed / flashed to fit your car. If you want
to move one Mechatronic from one car to another I might be able to
help you with the software.
