Operating principle of DSG. DSG gearbox: pros and cons, strengths and weaknesses of “DSG. What is a DSG gearbox

Modern life cannot be imagined without cars, and city driving should be as comfortable as possible for the driver. Ease of driving is ensured using various transmissions (automatic transmission, robotic gearbox).

The robotic box is very popular due to its smooth movement and economical consumption fuel, the presence of a manual mode, which allows you to adjust your driving style to the driver’s needs.

Operating principle of the DSG gearbox

DSG- manual transmission, equipped with an automatic drive for changing stages, and consisting of two clutch baskets.

The DSG box is connected to the engine through two clutches located axially. The odd and rear stages operate through one clutch, and the even stages through another. Such a device provides smooth shift stages without reducing or interrupting power, providing continuous transmission of torque from the motor to the drive axle of the wheels.

During acceleration in the first stage, the gears of the second gear are already in mesh. When the control unit transmits a command to change gears, the hydraulic gearbox drives release one clutch and clamp the second, transferring the torque from the motor from one gear to another.

Thus, the process occurs to the extreme stage. When the speed decreases and other conditions change, the procedure is carried out in the reverse order. The stages are changed using synchronizers.

Changing stages in the DSG box is carried out at a high speed, inaccessible even to professional racers.

What is mechatronics in automatic transmission

Both clutches and gear changes are controlled using a control unit consisting of hydraulic and electronic components and sensors. This unit is called Mechatronics and is located in the gearbox housing.

Sensors built into Mechatronic monitor the condition of the gearbox and monitor the operation of main parts and assemblies.

Parameters monitored by Mechatronics sensors:

• number of revolutions at the input and output of the box;
• oil pressure;
• oil level;
• working fluid temperature;
• location of stage switching forks.

On the latest models of DSG boxes, ECT is installed ( electronic system, which controls the change of stages).

In addition to the above parameters, ECT controls:

• vehicle speed;
• throttle opening degree;
• motor temperature.

Reading these parameters extends the life of the gearbox and engine.

Types of Direct Shift Transmission

IN currently There are two types of DSG boxes:

• six-speed (DSG-6);
• seven-speed (DSG-7).

DSG 6

The first preselective (robotic) gearbox was a six-speed DSG, which was developed in 2003.

DSG-6 design:

• two clutches;
• two rows of steps;
• crankcase;
• Mechatronics;
• gearbox differential;
• main gear.

The DSG-6 uses two wet clutches, which are invariably in transmission fluid, which ensures lubrication of mechanisms and cooling of clutch discs, thereby extending the operational period of the gearbox.

Two clutches transmit torque to the rows of gearbox stages. The gearbox drive disk is connected to the clutches by the flywheel of a special hub that combines the stages.

Main components of the mechatronics (electro-hydraulic module) located in the gearbox housing:

• gearbox distribution spools;
• multiplexer generating control commands;
• electromagnetic and control valves of the gearbox.

When the selector position changes, the gearbox distributors are turned on. The steps are changed using solenoid valves, and the position of the friction clutches is adjusted using pressure valves. These valves are the “heart” of the gearbox, and Mechatronic is the “brain”.

The gearbox multiplexer controls hydraulic cylinders, of which there are 8 in such a gearbox, but no more than 4 gearbox valves operate simultaneously. IN various modes The gearbox operates on different cylinders, depending on the required stage.

Gears in DSG-6 change cyclically. Two rows of stages are activated simultaneously, only one of them is not used - it is in standby mode. When the transmission torque changes, the second row is immediately engaged, switching to active mode. This mechanism of operation of the gearbox ensures gear changes in less than a split second, while the movement of vehicles occurs smoothly and evenly, without slowness or jerking.

DSG-6 is a more powerful robotic gearbox. The torque of a car engine with such a gearbox is about 350 Nm. This box weighs about 100 kilograms. Transmission oil for DSG-6 requires more than 6 liters.

On this moment DSG-6 is mainly installed on the following vehicles:

• Seat (Alhambra, Toledo);
• Skoda (Octavia, SuperB);
• Audi (TT, Q3, A3);

DSG boxes are equipped with Tiptronic, which switches the box to manual control.

DSG 7

DSG-7 was developed in 2006 specifically for economy class cars. DSG gearbox weighs 70-75 kg. and contains an oil volume of less than 2 liters. This gearbox is installed on budget cars with an engine torque of no more than 250 Nm.

At the moment, DSG-7 is mainly installed on the following cars:

• Audi (TT, Q3, A3);
• Seat (Leon, Ibiza, Altea);
• Skoda (Octavia, Fabia, SuperB);
• Volkswagen (Tiguan, Golf, Jetta, Passat).

The main difference between the DSG-7 and the DSG-6 is the presence of 2 dry clutch discs that are not in the transmission fluid. Such changes made it possible to reduce fuel consumption and reduce the cost of service.

Advantages and disadvantages of robotic automatic transmission

A robotic gearbox has its advantages and disadvantages compared to other transmissions.

Advantages of the DSG box:

• reduced fuel mixture consumption (up to 10-20%);
• possibility of manual control, similar to ;
• no loss of power when changing stages;
• smooth movement of the car;
• high dynamic characteristics a car equipped with a DSG gearbox;
• reducing the time required for acceleration;
• possibility of automatic and manual gear selection;
• comfortable driving of a car equipped with such a gearbox;
• the absence of a clutch pedal and the usual selector lever, which does not cause difficulties when switching from a car with a classic one;

Disadvantages of the DSG box:

• the high cost of a car with DSG compared to cars equipped with other types of transmissions;
• occasionally the robot slows down and does not keep up with the dynamic acceleration of the car, changing stages with a slight delay;
• mechatronics is one of the weak points in the DSG box, malfunctions periodically occur in this unit;
• if a malfunction occurs in the mechatronics, it must be replaced, since it cannot be repaired;
• reduced gearbox life;
• Mechatronics malfunctions are caused by frequent temperature changes, which is especially important in winter;
• the service life of DSG-7 and its components is noticeably shorter than that of DSG-6;
• increased heating of the box due to continuous activity of the preselector;
• increase in the cost of servicing a robotic gearbox;
• difficulty of repair robotic box, which not many service stations can implement;
• not installed on SUVs and other powerful vehicles;
• repairs are expensive, in some cases it is necessary to completely change the DSG.

• timely maintenance of the DSG gearbox (replacement of transmission fluid according to regulations - no more than 60,000 kilometers, troubleshooting);
• warming up the robotic gearbox by briefly keeping the car in a standing position after starting;
• smooth movement after warming up for 1-5 kilometers from the moment you start driving;
• avoiding wheel slip;
• when stopping for more than 1 minute, it is recommended to switch the DSG gearbox selector to neutral mode;
• when driving on snow and ice, it is recommended to turn on the “snowflake” mode, if available;
• during dynamic driving and fast acceleration, it is advisable to move the selector lever to the “sport” position;
• when passing each Maintenance it is necessary to diagnose the DSG box and perform initialization;
• the accelerator pedal must be depressed smoothly, even in manual mode;
• It is advisable to carry out acceleration in manual mode, and smooth driving and braking in automatic mode;
• parking the car from the DSG box in the “neutral” selector position with the obligatory inclusion parking brake(handbrake).

The robotic gearbox is, in fact, an improved manual transmission, the gears in which are switched using mechatronics based on various parameters read by sensors. If you follow certain recommendations, you can significantly extend the service life of the robotic box.

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 frequent 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 a key feature of the DSG that 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 sequential connection 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 frequent malfunctions touches 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 level oil or due to improper assembly (or transmission adjustment) after its repair.

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. Further with the box they begin big problems. 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 mechatronics 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 breakdowns 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 for this you need to have 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.
• Possibility of working 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.

In 2011, VAG Corporation began actively promoting robotic gearboxes on the market. Such mechanisms were not previously highly valued, since there were traditional automatic machines with a torque converter, which were famous for their greater reliability and maintainability. But the pursuit of environmentally friendly cars (albeit indicative), as well as the fight for every gram of gasoline in terms of fuel consumption, forced the company to install DSG gearboxes on almost all of its cars. And before this, robots existed and were installed on some modifications of VW Group cars. But since 2011, two main versions have appeared - DSG7 and DSG6. The first option was most often found on small cars like the German-assembled Polo, Golf, Jetta. But the second option is installed on Passat, Superb and many other flagship cars of the concern. Differences in design are due to different types clutches, as well as a slight modification of the 6-speed gearbox in terms of technology.

Unfortunately, the opinion about DSG technology in Russia is based on the 7-band robot, which turned out to be not very reliable and not the most successful in terms of design. Today, even a 7-speed gearbox no longer offers the troubles that used to exist on cars with this mechanism. Regarding the 6-band automatic device, then this robot showed a minimum of problems and continues to show the same high level quality. Today we will take a closer look at the design of this unit, talk about the resource, features and operating recommendations. This will help you more accurately understand the features of the equipment and be more confident in choosing a specific type. automatic transmission gears in the process of selecting and purchasing a car. The article will also give an idea of ​​how the DSG6 differs from all its brothers.

Design features of the 6-band DSG

The DQ200 7-speed gearbox is a real tragedy for motorists in Russia. Already during the warranty period, many noticed problems with this device. It's all about the design of the dry clutch (even if it's a double clutch). The clutch mechanism was clearly designed to save money, so it caused jerky gear changes, problems with the survival of discs, bearings and all other elements. After just a couple of years of operation, it was necessary to make expensive repairs and experience financial difficulties if the machine had already been discontinued.

DSG6 (DQ250) has a completely different design:

• a wet clutch lasts much longer, sometimes exceeding the service life of the gearbox itself, so there were initially much fewer problems and troubles with this mechanism than with a 7-speed gearbox;
• the mechatronics were made of much higher quality, since this unit was intended for the elite market, so no savings were made on it, creating only high-quality and proven technologies;
• shifts are much more imperceptible, the operating comfort of cars with DSG6 is higher not only because of the heavier body, this is due specifically to the design of the gearbox;
• in 2013, this unit was seriously modernized, changing the shape of the case, now the box works perfectly, it does not need to be removed to replace suspension parts, as was the case before;
• There are no problems with the clutch at all, it should be noted that this greatly distinguishes the DQ250 from all other Volkswagen automatic machines and robots, but you need to take into account the specifics of the box’s operation.

The 6-speed robot not only turned out to be more reliable and comfortable than its counterparts, but also became an important investment project for VAG. They invested money in it actively, ignoring the DSG7 with monstrous problems. So cars with robotic gearboxes with 6 steps can even be taken second-hand, especially if it is a vehicle manufactured after 2013. The latest modification of the gearbox turned out to be the most successful, and this is proven by feedback from the owners.

Service life and mileage - basic information about DSG6

This box was developed back in the early 2000s, but in Russia it began to be actively sold only on the Passat B6 recent years release. Also Passat B7 in almost all trim levels with automatic transmission has exactly this gearbox. Practice shows that even 6th generation Passats continue to operate perfectly well today with this robot without unnecessary repairs and expenses, and the mileage on the cars can exceed 250,000 km.

The resource is influenced by many factors:

• quality of service - please note that the manufacturer gives an overestimated oil change interval; it is recommended to change lubricants more often to avoid increased wear;
• quality of operation - it is better not to drive with DSG, it can damage the gearbox much faster than its factory service life ends, you can break the gears or overheat the pinion axis;
• warming up - before starting to operate the machine, you must turn the box into mode D or R and wait about 30-40 seconds for the lubricants to pass throughout the entire structure of the unit;
• age - resource is measured not only in mileage, but also in age restrictions, but so far all DSG boxes are young enough to take this factor into account when determining the life of the gearbox;
• modification - the very first versions of the robot were the most successful, modifications after 2013 are also encouraging, intermediate versions turned out to be less practical and reliable (but not critical).

The main breakdowns are associated with licked gears, a broken pinion axle, and wear of the differential bearings, but you will read about the reasons below. When talking about the resource of the box, you need to take into account the driver’s accuracy and the quality of service. It is enough to pour low-quality oil into the box a couple of times in a row to cause complex breakdowns and increased wear. It is better to service components using original materials or similar options in terms of characteristics, but from trusted manufacturers.

Chip tuning is the worst enemy of the DSG6 box

The DQ250 gearbox, like its younger brother DQ200, does not tolerate anything related to engine tuning. At the factory, the corporation configures the software of the box itself so that it gear ratios exactly matched the power and torque power unit. Tuning can easily increase engine power by 40-60 horsepower, but such a breakthrough will be unbearable for the gearbox. Most likely, already 10-20 thousand km after chip tuning, the robot will begin to die little by little.

The reasons for rapid wear of parts are as follows:

• artificially increased engine power was not intended by the manufacturer for your model, even though tuning shops claim that all the hardware is in different modifications identical;
• DSG boxes have their own brains, and they simply go crazy if the basic characteristics of the engine change even a little, in this case the robot will simply not have time to switch;
• the gears of the gears will stick together as soon as the engine torque changes, since an unexpected mode of operation of the clutch will begin, and the ECU will give incorrect signals;
• with the help of chip tuning, the car’s low-end power increases significantly, and jerks from traffic lights become a pleasure for the driver, but a factor of death for the robotic gearbox;
• with sharp jerks, even with standard firmware, the satellite assembly can overheat, this must be understood in any sporting mood while driving a car with a robot, and not only a German one.

The problem of chip tuning has been mentioned many times German manufacturers cars. Almost all gearboxes, except manual ones, suffer from this unauthorized action. So on cars with DSG6 it is better to refuse to increase power through software. Also remember that for each machine and even for each modification at the factory, specialists separately configure the robot and create their own software for different cases.

How to extend the life of a German robot?

DSG6 can travel up to 300,000 km and up to 20 years without much intervention in the system. Of course, this resource is listed for optimal conditions operation of the vehicle. In most cases, conditions are not ideal, so nodes fail faster than you expect. The situation is especially difficult when buying a used car with a robotic gearbox. In this case, it is very difficult to predict any timing and resources.

You can extend the operation of the DSG6 robot on your machine in the following ways:

• change the oil once every 40,000 km, this will not increase your maintenance costs too much, but will help to significantly extend the life of the gearbox, this is an important point for every owner;
• do not start abruptly, since a dynamic start of the trip not only forces the mechatronics to work under stress, but also greatly affects the gears, it is better to play it safe and develop smooth trip modes;
• warm up the gearbox before driving, this is indicated in the recommendations for the operation of the first gearboxes, but then the Germans removed this advice due to complex environmental requirements in Germany;
• fill only original oil in the gearbox, otherwise even the highest quality replacement may not work as efficiently and cause increased wear of the mechanism and chipping of the teeth on the gears;
• monitor the quality of gear shifting and contact the service station in time if something has changed, since working with low level oil will cause rapid breakdown of the gearbox.

You should also abandon chip tuning, which has become the number one enemy of modern robotic gear shift mechanisms. You should pay attention to all vehicle operating parameters. In particular, it is important to take into account fuel consumption, smooth shifting, sound of the mechanism, vibration and other features. This way, you can independently determine the onset of problems and contact service in time. This will help significantly save money on repairs and maintenance, since serious breakdowns of the DSG6 sometimes lead to a complete replacement of the unit.

We invite you to watch a video with a presentation of the features of the VAG 6-speed robot:

Let's sum it up

Modern technologies require investment of certain funds from the owner. If you think the boxes DSG gears are designed for a long service life, and are also designed to save money for their owners, then you are wrong. Today, gearboxes like the DSG6 are created for the commercial benefit of the companies that created them, and this is no longer hidden even by the manufacturers themselves. But we must proceed from what we have. And if we compare the 6-band robot of the VAG corporation, it turns out to be much better and more reliable than many other solutions of its class and type.

It must be admitted that Volkswagen already far from what it was 20 years ago. Today, the equipment of this brand is already designed for 10 years of relatively normal operation. In the future, this interval will be shortened. Businesses are forced to do things with low consumption to increase sales in the future. You need to come to terms with this and find a middle ground for yourself. If you want an incredibly reliable and high-quality transmission, buy a car with a manual transmission. And DSGs are designed for comfort, fuel economy and technology of your car. What do you think about buying a car with a DSG6 gearbox?

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 of Volkswagen robotic gearboxes, however, it 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 consumption and increases the fuel efficiency of the 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 models cars 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 efficiency of the 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 vehicle systems;
• 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. IN total there are eight of them, 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 typical 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 the fault to be identified using computer diagnostics. To fix the damage, a replacement will be required. friction clutch assembled or individual disks of this unit. 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 a 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 appear when the car engine is cold started. 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 during sudden acceleration or braking of 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. Price Vehicle with a robotic gearbox is higher than cars with automatic or manual transmission.

Nowadays, cars are equipped with different types of boxes. The times when only “mechanics” were installed on cars are long gone. Now more than half modern cars equipped with other types of gearboxes. Even domestic manufacturers began to slowly switch to automatic transmissions. The Audi-Volkswagen concern introduced almost 10 years ago new transmission- DSG. What is this box? What is its structure? Are there any problems during operation? About all this and more - further in our article.

DSG characteristics

What is this box? DSG is a direct shift transmission.

It is equipped with an automatic gear shift drive. One of DSG features"mechatronic" - the presence of two clutches.

Design

This transmission is connected to the engine through two coaxially located clutch discs. One is responsible for even gears, and the second for odd and reverse gears. Thanks to this device, the car drives more smoothly. The box smoothly switches gears. How does a DSG automatic work? Let's take an example. The car is driving in first gear. When its gears rotate and transmit torque, the second speed is already in mesh. It spins idle. When the vehicle shifts to the next gear, the the electronic unit management. At this time, the hydraulic transmission drive releases the first and finally closes the second. Torque moves smoothly from one gear to another. And so on until sixth or seventh gear. When the car picks up a high enough speed, the transmission will switch to the last stage.

In this case, the gears of the penultimate gear, that is, the sixth or fifth gear, will be in “idle” engagement. When the speed decreases, the clutch discs of the robotic gearbox will disengage the last stage and come into contact with the penultimate gear. Thus, the engine is in constant contact with the gearbox. At the same time, the “mechanics” retracts the clutch disc by pressing the pedal, and the transmission is no longer in contact with the engine. Here, with two discs, torque is transmitted smoothly and without power interruption.

Advantages

Unlike a conventional automatic transmission, a robotic DSG automatic transmission requires less load, thereby reducing fuel consumption. Also, unlike a simple automatic transmission, the time between everything is reduced due to the presence of two clutches. In addition, the driver can independently switch to tiptronic mode and mechanically control the gear shift. The function of the clutch pedal will be performed electronically. Nowadays, Skoda, Audi and Volkswagen cars are equipped with an ECT system, which not only controls gear shifting, but also controls opening throttle valve. Thus, when driving, it feels like you are driving in one gear. The electronics also reads many other data, including engine temperature. The manufacturer claims that the use of the ECT system allows you to increase the service life of the robotic gearbox and engine by 20 percent.

Another plus is the ability to select the transmission operating mode. There are three of them: winter, economical and sports. As for the latter, the electronics change the gear shift point to a later one. This increases, but fuel consumption also increases.

Transmission problems and malfunctions

Since the robotic DSG gearbox is a complex electromechanical device, it is susceptible to various breakdowns. Let's look at them. So, the very first problem is the clutch. It is worth noting the wear of the basket and driven disk, as well as increased load on release bearing. A sign of malfunction of these mechanisms is clutch slipping. As a result, torque is lost and the vehicle's acceleration dynamics deteriorate.

Emergency mode occurs. What does this mean? A light appears on the instrument panel, the car begins to twitch and has trouble starting from a standstill.

Acutators

DSG problems also affect the actuators. This is an electromechanical gear shift and clutch drive. With frequent use and high mileage The so-called “brushes” wear out. A circuit break cannot be ruled out electric motor. A sign of malfunction of the actuators is a sharp start and “jerking” of the car. This symptom also occurs when the clutch settings are incorrect. Therefore it is necessary to produce computer diagnostics. Each car brand has its own fault codes.

About the 7-speed DSG

We already know what kind of box this is. Fundamental differences There are no six- and seven-speed “robots” in operation.

But statistics say that it is precisely these boxes that are most susceptible to breakdowns. If we consider the seven-speed “robot” separately, it is worth noting the problem of the mechatronic control unit and the dry clutch. The latter is subject to severe wear, especially when switching to increased or. As a result, it wears out and the box goes into “emergency mode”. Slippage and problems occur when starting from a standstill and changing gears. The Volkswagen manufacturer itself provides a warranty period of 5 years. During this time, more than half of the cars with such a gearbox require clutch replacement. This is the whole problem with this transmission. Therefore, if the car is more than five years old, all responsibility falls entirely on the shoulders of the car owner. And he will change all the components in this box at his own expense.

Mechatronic

Problems exist not only with the mechanical part, but also with the electrical part, namely the control unit. This element is installed in the transmission itself. Since it is constantly exposed to loads, the temperature inside the unit increases.

Because of this, the contacts of the unit burn out, the serviceability of valves and sensors is impaired. The valve body channels also become clogged. The sensors themselves literally magnetize the wear products of the box - small metal shavings. As a result, the operation of the electrohydraulic control unit is disrupted. The car begins to slip, drives poorly, until it comes to a complete stop and the units stop working. Also worth noting is the problem of clutch fork wear. As a result, the box cannot engage one of the gears. There is a hum when driving. This is due to wear and tear. This gearbox is installed on cars different segment. But even on expensive cars These malfunctions cannot be ruled out, although its components are designed for greater service life and loads.

How to extend the service life?

Due to frequent calls to dealerships, the concern itself began to advise car owners on how to extend the service life of the box.

In order for the transmission elements to be subjected to less stress, when stopping for more than five seconds, the manufacturer recommends moving the gearbox selector to the neutral position.

Conclusion

So, we found out what it is. As you can see, despite many advantages, it has many problems. Therefore, it is reasonable to drive such cars only if it is under warranty. Car enthusiasts do not recommend purchasing such cars on the secondary market if they are more than 5 years old. The reliability of these boxes is a big question.