DSG Gearbox Diagnosed explained Fixed
In this video we diagnose a dry clutch Dsg transmission.
Whe need to take it apart to find a short circuit, during this procedure i'll take
you thru the internal parts and explain how they work.
Enjoy!
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Safety Recall 34F6 on 06 Dec 2013: Over time, the internal gearbox lead frame may corrode due to certain gearbox fluid additives used in original gearbox filling. If corrosion deposits collect between electrical wiring, an electrical short in the power supply may result in blown gearbox fuses and the deactivation of the gearbox hydraulic pump or mechatronic unit. The driver will immediately be alerted by a flashing gear indicator warning lamp in the instrument cluster and the vehicle will lose motive power but can coast to a stop. Loss of motive power while driving may increase the risk of a crash.
- Corrective Action Replace existing synthetic gearbox oil with a new, mineralbased oil with non-corrosive additives to prevent future failure: static.nhtsa.gov/odi/rcl/2013...
Just a tip for those that don't know, in DSG dry-clutch models built before 2015 their is a design issue where the pressure accumulator can crack at the base. This results in a pressure loss that prevents gear changes happening. There is a recall in some countries and VW/Skoda/SEAT are replacing the mechatronics units as a warranty issue.
North America?
Is there a listing of the countries. Example, Jamaica 🇯🇲
What about uk cause shit mines playing up like mad
@@RG-bx1vd what car
@@S-u-p-a seat Leon 18 plate
UPDATE! It's the Gearbox oil responsible not the hydraulic fluid. I changed the Gearbox oil after the video. Safety Recall 34F6 on 06 Dec 2013: Over time, the internal gearbox lead frame may corrode due to certain gearbox fluid additives used in original gearbox filling. If corrosion deposits collect between electrical wiring, an electrical short in the power supply may result in blown gearbox fuses and the deactivation of the gearbox hydraulic pump or mechatronic unit. The driver will immediately be alerted by a flashing gear indicator warning lamp in the instrument cluster and the vehicle will lose motive power but can coast to a stop. Loss of motive power while driving may increase the risk of a crash. - Corrective Action Replace existing synthetic gearbox oil with a new, mineralbased oil with non-corrosive additives to prevent future failure: static.nhtsa.gov/odi/rcl/2013/RCMN-13V568-9034.pdf
oh right the board is submerged in the main gearbox oil got ya thanks for putting me straight on that one
That's interesting, will VW be paying for the repair and fluids? I wonder were all the factory testing time went.
Thank you dan!!!
@@philthejet massive recall on DSG, VW just cant seem to do the right thing in most cases, a mate went thru hell to get his Golf R DSG fixed, and it was only a few months old//
mixalis Hi, Just curious. What was the dealers response? I mean, if only a few months old, it should be difficult not to carry out any repair under warranty... (even for VW;)
I've always been a bit unsure of the wizardry that goes on inside a DSG gearbox. What an excellent video, everything is clearly explained, good audio and good camerawork.
Thank you very much 👍
bravooooo
Best DSG video ever! Wonderful explanation
Awesome Explanation. Thanks
@@Diagnosedan k
I wish everyone of us had his own Dan as a mechanic
I've come pretty close!
But where in America is he?
@@forevercomputing he's Dutch
🥺 Dan is a hero
Hahahahaha 😂
More people like you Dan !!! Amazing enthusiasm and patience. Thank you
Thoroughly enjoyed it Dan. And even though there was a TSB it was good to see the tear down to prove it and that no other apparent issues were present. Thanks!
I thought the TSB was for the gearbox oil but was it actually for the hydraulic oil in the mechatronic unit?
It was great to have you in the live chat!
@@meeder78 And you were right. Read the pinned update from Dan at the top.
Am always impressed Dan the way you keep the workshop clean and tidy and everything that you might need is right there at hand, I wish a lot of workshops would do the same!
What a brilliant video.There is absolutely no need for modern cars to be so complicated.Dan you will never be short of work!
Hey Dan , just stumbled across you channel . What a great tutorial on the DSG gearbox . I owned one in a VW EOS 2008 model , never had any problems with it . As a car guy I really appreciate the fusion of the two manual gearbox & clutch setups , controlled by the mechatronic and your very good explanation of how it works . Great work !
I love the teardown and explanation. You are a natural teacher.
Thank you 😀
Brilliant video and explanation Mr. Dan. This is next level explanation of a complex fault on a dsg gearbox. You make it seem so easy to repair. Thank you.
Dan youre awesome,i'm in jamaica and i watch your videos and learn so much,cant tell you how much youre appreciated.
Only caught the end of it but have the pleasure of watching from the start, even VW gearboxes are interesting on Diagnosedan!
Ha ha thanks, they are very interesting 🙂
@@Diagnosedan its a simply gearbox, why they can do it right? NOW they using mineral oil....... Same with engine oil. I use still till today mineral oil..... these are better for the engines.
That was seem quick and clear Diagnosis Dan I wish I can be like you.
An excellent talk, concise and precise, very informative. Thank you!
A fascinating insight into a dsg gearbox electronics. As a motorcycle mechanic myself I find this to be a really well presented and step by step process of elimination to find the reason for the short circuit.
Old school auto tech here, what a perfect training lesson on dual clutch gearbox, full description of mechatronic unit operation and repair and a good Diagnostic route to find it. Enjoying each one I am running into and love the logic bombs you work through.
For us not initiated that TSB is "Technical Service Bulletins". Great work Dan!
Yet again another superb video; you are certainly a master of both automotive fault diagnosis AND producing clear, interesting, informative, enlightening and educational videos, thanks Dan, I enjoy every second watching you work, every single time.
Wow that's a great comment Richard, you made me smile
I really like your talking approach to the audience. You make your diagnostic methodology and the reasons for it quite clear. This is quite a bit better than doing it only while you are doing the work. It's very good to discuss the plans first. Thx very much.
The most mind blowingly clear description and diagnosis of the dreaded VW dry clutch DSG setup. I’m no longer afraid of DSGs.
Dan, I have so much respect for your approach to your craft my friend. Not only do you attempt to find the part causing the symptoms, but you always effort to find the “why” behind the problem. Which is what those with truly talented gifts for repair indeed do. I Enjoy all your videos!
That's a great comment 👍👍 Thanks!
Bloody hell Dan. 13:50 With a few words I finally understood how DSG works and why its called dual clutch.
Great!👍👍
Agreed, and great teardown overall. So, one of the two clutches is always engaged at all times?
@@LeverPhile Except when at a stop. But if stopped on a hill, don't use the throttle to hold the car like you can with a real automatic because that slips the first gear clutch rather than a torque converter.
@@andyanderson1612 Right, neither clutch engaged at a stop. But absolutely no way I'd use the transmission to hold the car on a hill ... auto, manual or DSG ...
The best job I have ever seen on a car. Intelligence and putting a good hand can do miracles!
Dan, I wish there were more professionals like you out there...
I was supposed to be on a DSG repair/overhaul training seminar this week, but it was cancelled for obvious reasons... Good thing you came to the rescue!
Great timing huh😂
We r manufacture mctronic units from sri lanka
@@akilaperera1983 for vw?
Dan, as always enjoyed your content. Love your analytical and problem solving approach. 10/10 also for your video editing skills.
Thanks alot Dave!
Thank you, Mr. Dan, I really enjoy every episode you upload. Now I am thinking of opening a car repair shop despite the money shortage, but I am determined to do that
Excellent video. Clear speech, logically laid out, every step visible. Uncut shot of battery diagnosis was really cool. I'll return to your tidy workshop soon 👍
Thank you for sharing. I’ve wanted to know more about DSG since I started driving my a few years back. 👍🏻
Thanks for watching 👍
Great video! For checking a 3-phase-motor you can also just make sure, the resistance between the phases is the same and infinite against the housing. Way less effort, same result ;)
Diagnose Dan is my new binge watch channel. Absolutely brilliant content
Thank you very much Dan. You've explained the functions of a DSG gearbox in a way that even i can understand.
What a great video, it shows why i was presented with a bill of £2500 when I had the same problem with my Seat.
Thanx Dan, ur explanation makes work look simple, awesome video♥️
Hey Dan you did a great job with this video, your a born natural. Very interesting well done.
mate, you're the epitomy of a legend, i watched every second of that video and it felt like a 2 minute video. love your work mate!
TSB’s are life savers. DD did it again as always!🙏
Nice work Dan, I love your thoroughness.
Thank you very much 😀
Love watching a master of his craft well done Dan greetings from Australia cheers mate 👍
Thanks Damien😁
Thank you so much DAN. I just learned so much about the DSG. Your teaching properly educated me and also saved me so much money on my 2009 Audi tt DSG repair. Thank You Dan!!!!
Super clear explanation on a piece of wizardry! You have a knack for teaching and making it understandable, well done!
i love how you always find the root cause of a failure.
Thank you 👍
Looking forward to 'diagnosing this together'! Or maybe I'll just sit and watch you do it. 😉 Keep them coming Dan. 👍🏻
Abbott Automotive 🤣🤣☺️ look at that, fixed it without even getting my hands dirty. 💪🏽👌
@@HandyC haha! yes, it wasn't a bad one was it. 😉 😂
Why did you let me do all the dirty work😉
@@Diagnosedan we all know you love getting dirty
@@Diagnosedan you were doing such a good job so I thought I'd leave it to you. Plus I was just supervising. 😋
This is one of the best auto channels I've ever seen.
Great video! Suffered this issue on my 2012 Skoda Fabia a few years ago. Learned a lot about these gearboxes and Mechatronic units since.
Can't wait, hope business is still ok, stay safe Dan!!!!
Work is very slow but we are all Safe.
Good job Dan! Oil specification is very important! For those manual gear box required GL-4 oil, don’t use GL-5 oil because the additive for EP of GL-5 contains sulphur which could cause wear of soft metals of synchromesh gears, the worn soft metals caused a short circuit in the VW dry DSG.
HI DO YOU KNOW WHATS THE RIGHT OIL FOR 2010 VW GOLF DSG GEAR BOX
You just helped me understand my Passat TDI with a DSG, this is the first DSG I have ever owned and before I bought my Passat I'd never heard of a DSG transmission. Tusen takk!
Utterly brilliant education there Dan. Thanks a lot and I mean that. In 1970 I did 'Advanced Motor Mechanics' at college and then ran a little repair garage. All I learned about ZF and Borg Warner auto boxes was that they are so complex you don't take them apart, give them to an expert. Your video here tells me I can probably fix the DSG on my Golf out in my driveway. Now I have no need to go looking for a brand new 1990 Mercedes :)
Love your videos, very informative. it's amazing the technology that go's into modern vehicles. Thanks
Thanks for watching 👍
Thank you mr Dan. Found that really interesting. keep them coming please. Take care 👍
Thanks for watching Chris
Such a great video. So clear and now I understand exactly how the DSG mechatronics function. EXCELLENT WORK!
You're my hero Dan, if I can be half as good as you one day I'll know I made it
Great video Can , we struggle in the UK for TSB's , when you try to speak to dealer workshop's, we've never had that problem sir , Lying basts they are , very good info for the head filing cabinet, I use wurth trip fuses for repeat blow testing to save on fuses , I mentioned before about second with eggshells, now it's ground walnut shells being used , take care , thanks for the info , good idea about the battery test , imagine all the relearning to be done again after repairs a week later
Thanks for the comment, Stay safe Mike
Ford don't let you get wiring diagrams
Excellent tutorial, beautiful lighting and camera angles! I would love to see you do a DSG fluid change on a VW GTI.
Truly excelent, when i count possibility about this Yetti coming from factory with manual gearbox, then we ended without this video, and milions of peoples worldwide can spare on repairs, when something like DSG doesnt exist. Servis intervals are too short... 🤣
Hello, Great idea , The GTI has just entered the family and need some care. Thanks for this great channel Tigo
Great video! As a mechanic I found this very helpful and informative.
Hi Dan You are a amazing diagnostics technician which I ever scenes.im working in volvo truck dealership in Australia. and your videos helping me alot for gained up my diagnostics skills. Thanks alot
Good video as always ! A recommendation from my side. First remove the TCU from the hydraulic block and only afterwards remove its cover. Inside the sealed enclosure you have either a ceramic substrate with bare die electronic components (gen. 1) or a HDI PCB with the same bare die components (gen. 2). By removing the cover while you are still disassembling the unit you risk touching the board. If that happens there is a high risk of damage to the wire bonds or the actual bare die electronic components which are a lot more fragile than the normal, packaged ones. Keep up with the good work !
Thanks for the advise, i clearly don't pull these apart daily.😉
From your experience what causes the main fuse for the mechatronic to be blown every time the ignition is turned on?
👍
@@shimon2476 - Safety Recall 34F6 on 06 Dec 2013: Over time, the internal gearbox lead frame may corrode due to certain gearbox fluid additives used in original gearbox filling. If corrosion deposits collect between electrical wiring, an electrical short in the power supply may result in blown gearbox fuses and the deactivation of the gearbox hydraulic pump or mechatronic unit. The driver will immediately be alerted by a flashing gear indicator warning lamp in the instrument cluster and the vehicle will lose motive power but can coast to a stop. Loss of motive power while driving may increase the risk of a crash. - Corrective Action Replace existing synthetic gearbox oil with a new, mineralbased oil with non-corrosive additives to prevent future failure: static.nhtsa.gov/odi/rcl/2013/RCMN-13V568-9034.pdf
Awesome!...really clearly explained Dan, thanks!
My pleasure 😀
You are THE MAN! . Thinking of purchasing a Audi with DSG and this gives me a great insight into the Gearbox design weakness.
Dan University. Always brilliant and the best. Just amazing what everyone can learn from this gentleman!
Thank Q Dan the man done it again.... very informative Webinar.....
Thanks for attending
Dan, there is a simpler way to test for short circuits. Instead of installing a new fuse, connect a 12 V tester to both fuse terminals. In the event of a short circuit, the light in the tester will turn on and stay on (12 V on one side, short to ground on the other). Otherwise, it can turn on a split second, dim and turn off. Thanks for your effort for this video.
❤❤❤
Fantastic video. I have the same problem and this video has thoroughly informed me how these work and what's involved in repairing the issue. Brilliant work, thank you.
Very interesting teardown that shows the complexities of the DSG transmission. Thanks Dan for posting! I know was few years ago but just saw it.
Thank you Dan for as always interesting and excellent content! Just like to add, if you like to use an oscilloscope to measure three phases, that you can, if there is no neutral point like the three phase motor in your video, add three equal resistors from each of the three phases into a star point. Well, now you have a neutral point and can connect three channels to each of the phases and ground to the star point made up of the three resistors. It could be done just for fun! ;-) Keep up the good work Dan, love your videos!
Thanks for the comment
@@Diagnosedan Hi, how do you depressurize the accumulator before opening? can it shoot out and injure someone?
Thank you, my friend, for the information. I have a problem with my car, it is byd, the bst transmission system, and I want to test the clutch lever No. 2, please. If I have any other program to communicate, it is preferred.@@Diagnosedan
Thank you for everything man It was amazing
That's great to hear 😁
I'm a mechanic in Las Vegas so I don't see alot of the same cars you do, but your diag. routine is top notch. I really enjoy your videos. I never thought I'd find someone as good as Eric O. at South Main Auto, but I was clearly wrong. Looking forward to your next video.
Thank you; I now understand just how these DSG gearboxes work. Awesome video.
Great dissection of the inner guts of DSG. Dear Dan, do you also get an extra bolt or screw leftover after reassembling things ?
Brilliant mate that’s a great video, learnt a lot as usual!
That's great Michael
I am a proffesional tech. This is a very quality learning video. For the pros and a novice tech. Thanks diagnose Dan
This is one of the best video for Explanation of DSG Gearbox . Really highly recommended. Thank you very much for that.
Keep those great videos coming... my wife is driving me up the walls!!!
Ha ha ha 😂😂
I love the way he's so casual about it. Taking the pump apart, etc. The big problem is that a lot of mechanics are afraid to take things apart. They only replace the parts and don't try to know how they work. It's not rocket science, nor is it magic. I love the video. Well done, Dan.
you took it apart = you broke it (even if you actually haven't) replacing is safer from the POV of the tech...
Easier said than done.. easy for you to say and criticise other people
Wow I knew the DSG box was a great feat of engineering but never realised it was so complicated. Dan you are a magician sir,,,,truly knowledgeable. Great video. Thanks for posting.
Your videos are spot on. You're thorough, and clear in your diagnostic procedure. You're great at your profession.
Thanks for the comment it's appriciated
Brilliant video as ever Dan. Sulphurised oil eats copper and attacks copper alloys. Well known fact. Wonder how the VW Engineers missed that? My Dad had a VW Beetle and it kept jumping out of gear. Beautifully made car. He blamed himself for a while for failing to put it in gear properly. I said no, gearbox fault and indeed it was. Been off Volkswagens ever since!
I've had two cars with DSG gearboxes, and never had any issues with them, but they do give me the fear. I'm not sure how many people are out there who'll do diagnosis at this level. I now have a car with three pedals and a lever that you wobble around. ;-)
😂😂👍
I must admit its one of those reason I avoid these new fangled Automatics like the Covid. Old fashioned Slush boxes were slow and burned more fuel, but jesus they were simple. Manual for me too.
@@DasArab whaaa?? since when are torque-converter autos "simple"?? have you ever taken one apart and tried to put it back together, or seen those valve bodies?
@@raoulrr its simple, everything is on 1 shaft.... and valves follow oil pressure.
@@hdj81Vlimitedagreed
Still the best transmission I have ever had. I love my Passat TDi but I cringe when I see the complications and costs involved with these VW's. It's a pity VGA are criminal in their distain for owners. This presentation was epic. I learned so much. Thanks for the thorough education.
My videos teach me a lot you are a real professional. Please continue to upload more videos
If I have to rate 10/10 I’ll even give 20/10. U explain and show everything very well. Very helpful !
This is a great channel, I wish you done videos more often!
I want to start a small local shop and I love your videos reminds me of automotive school back in 2009.
I learned nearly all the basics about the system thank you so much sir dan
Amazing how many points of failure this transmission has. It's almost like there was a competition on who could make it fail the most ways. Excellent video as always!! One of the best channels to learn from.
Who won?😛
@@Diagnosedan Well, designing a transmission that totally fails because it's own gear oil leaked into itself makes you a good contender for first place! Absolutely ludicrous design in this day and age. There's no need for this. None.
This transmission makes me appreciate my 2001 Mercedes transmission.
Thanks for watching Marcus
Nothing more Bullet Proof than 722-5 Transmission.
Glad to see you still smiling, given the current pandemic. Many thanks for a most interesting presentation.
Just dropping a comment to give you some more traffic and help you grow. I used to be a mechanic and I am amazed at your diagnostic skills. You would be an excellent analyst in any field!
That was awesome, Dan! Very cool to see a DSG gearbox teardown and explanation! I'll stick to my regular old-school foot clutch for now...seems to be more reliable...until my left leg blows a fuse haha :D
Ha ha manuals must be rare in the States.
Yes, they are almost becoming exotic. Most people don't know how to operate a manual, and think of their car as an appliance :(
It's good to see that VW DSG use separate fluid to push the gear changes and a different one to lubricate the actual gearbox. Unlike the GETRAG DCTs that use the same oil to lubricate the diff, the gears and swill around the solenoids as hydraulic fluid which of course is a mental idea as the swarf particles clog the solenoids and end up causing lots of shift problems due to sticky solenoids plungers. Great video, do a DCT 450 and give us a look at one of those in pieces.
Maybe when i get an interesting one!
I believe the 6 speed, wet clutch versions utilized 1 fluid type. The 7 spd dry clutch versions, had 2 flud types, independent of each other. I could be wrong, but I have three 6 spds and have only ever used 1 fluid type.
The cleanest shop I have ever seen. Excellence as always.
I have seen this 3 times so far. Thank you for the great DSG video,
Maybe you can do a dq250 or any of the wet clutches.Cheers 🍻
No problem 😁
6 speed wet qlutch DQ250 would be cool and interesting
29:13 Me, when a new video is out.
me to :-)
Never forget to celebrate your accomplishments.
Ha ha ha😂😂
Mr Dan, your working procedures are very important 👏 👌 🙌 👍
Only subscribed recently and I’m working my way through all the videos. Time just flies by when I do. Thanks for such enjoyable videos and for making me less stupid by educating me! 🤓 If you’d have been my auto shop teacher in high school, I’d have become an automotive engineer. Keep them coming please! 👍
Always mechatronic failure, although I've seen clutch failure, flywheel failure, slipper bearing failure, solenoid and actuator failure.... the best is hydraulic pump failure! What a mess!
You forget the broken Acumulator 😉
@@Diagnosedan Totally, that looks awesome when they fail.
For the accumulator failure you have to be careful with disassemble. Last time we had a lot of problems with customers who putted the wrong oil in the mechatronic 😁
5:55 Too many useless devices making our lives more expensive!!!
Came here after seeing others commenting about @DiagnoseDan on Saving Salvages RS3 DSG Mechatronic issue. Am not mechanically minded, but found this video so interesting, and learnt what the DSG gearbox is and how it works. Excellent video, even for those of us non-mechanics!
I got the VW DSG 6 gear box that has given me night mares....this sheds a lot of light thanks @DiagnoseDan will definitely consult in case of any questions :-)