7 speed automatic transmission dsg. DSG gearbox: what is it? What is "ECT"

Direct Shift Gear Box (Direct Shift Gearbox) or DSG is a robotic gearbox in which there are two clutches at once, developed by the Volkswagen concern.

Structurally, such a box is a manual transmission, but gear shifting and clutch operation are carried out using computer-controlled mechanisms.

Of course, such a box has its advantages. Due to the double clutch, gear shifting is faster and easier, better dynamics, less consumption. One clutch is responsible for even gears, the other clutch is for odd gears. Due to this, the main problem of robots was solved, in sharp gear shifts at high speeds. This is where the positives end, however. The disadvantages of this box are very low reliability and high repair costs. They make used cars with DSG a real nightmare for second and third owners who buy a car that has run out of warranty.

The main problems and disadvantages of operating this box are the very rapid wear of the dry clutch, due to the not entirely correct operation of the mechatronics and its control unit.
There are, of course, other disadvantages to the design of the gearbox - contamination of the sensors, souring of the solenoids contacts, wear of other mechanisms (clutch release fork, shaft bushings, and so on.) Repair of the gearbox can be so expensive that if the warranty is out, then it is easier to change the gearbox to a new one. In addition, suppliers often have problems with spare parts, rare parts are on sale and they will have to wait for several weeks.

Despite the fact that the manufacturer fulfills all its obligations and the guarantee for the assembly is quite impressive, this checkpoint in Russia has generated serious passions.

Deputies of United Russia and representatives of the public movement "Automotive Russia" even wanted to ban the import of DSG-7 boxes into our country. Such behavior is not at all another unhealthy initiative of the authorities to address strange problems. Many meetings with journalists and Volkswagen experts end with legitimate questions: when will the engineers make the box reliable and its typical problems and disadvantages will be solved. The answers are always the same, they say, everything is fine with the box, follow the operating instructions, if something is wrong - there is a guarantee, the car with our gearbox drives quickly and economically. However, as noted by the drivers, not for long.

Volkswagen followed with a statement, the essence of which was that the company would fulfill all obligations to customers who encountered low-quality products, but only if the warranty was valid. At the moment, the official representation of Volkswagen in Russia gives guarantees for this unit, if the car is new, up to 5 years, or the obligation is valid for 150,000 mileage, depending on what comes first. In the event of a warranty case, company representatives will replace the failed parts and mechanisms or the box itself, if necessary, and completely free of charge.

Operating rules

In order for the box to live for a long time, you should familiarize yourself with the rules for its operation, read the instructions and understand how it works. Here are some tips:

1. For proper operation, the transmission should be warmed up before driving;
2. It is important to avoid any slippage and aggressive driving;
3. Overcome dense congestion in the S position without switching to neutral;
4. Oil should be changed every 50,000;
5. For a "dry" clutch, it is better to shift into neutral during long stops.

If you ignore the careful attitude to this mechanism, then problems will soon arise with it and expensive repairs will be needed.

Change of oil

Volkswagen writes that an oil change at these gearboxes is only necessary during repairs - the oil is filled for the entire service life, it is not recommended to change it while the car is in operation. If the gearbox has been repaired, then an oil change is necessary every 60,000 kilometers. Service station specialists who have already dealt with the repair of these gearboxes claim that in any case, an oil change is necessary every 50,000 kilometers, otherwise no one guarantees that the box will last a long time.

The DSG 0B5 has two lubrication systems (gearbox housing and mechatronics). The mechatronics unit has a different oil, designed specifically for 0B5. Under no circumstances should such oil be drained from mechatronics. Modification 0B5 was installed on the Audi A4, from where it migrated further to models A and Q.

If the oil change is done by hand, then another nuance awaits the motorist. There is no filler hole, a suitable hole can only be found under the battery. All problems are solvable if you know what to do.

Oil for replacement is suitable G52512A2, you need to fill in 1.7 liters (5.5 for a complete replacement). An oil change can be cheaper if you use an analogue of SWAG 10 92 1829.

In general, changing the oil is no different from a similar procedure for an automatic transmission.

Can a car with a gearbox be towed by a robot?

It is not recommended to tow a car with a DSG box. The box may fail from the transportation procedure itself, and in this case the warranty will not apply. The official service station may refuse to repair due to violation of operating conditions. It is advisable to call a tow truck. If this is not possible and the vehicle must still be towed, the following should be done.

1. Turn on the ignition;
2. Shift the gearbox to neutral (towing at speed is not recommended and may damage the gearbox).

Towing is allowed for a distance of not more than 50 kilometers at a speed of not more than 50 km / h.

The opposite situation, when another car needs to be towed by a car with a robot box, is also not safe. In extreme cases, it is necessary to transfer the box to manual mode and move only in first gear and it is better not to exceed the speed of 30 km / h.

Tow truck for transporting cars

DSG adaptation

Adaptation is a procedure for adjusting the operation of the gearbox and the mechatronics unit, which is necessary after repair and in some cases when the box does not work correctly. The procedure is simple and you can do it yourself. Usually adaptation is carried out through Vag Com. Vag Com is a diagnostic program that will allow you to "make friends" with a computer, diagnose and configure some systems. The program has a simple and intuitive interface, it takes up little disk space and it has its advantages compared to analogues. In order for the adaptation to be carried out correctly, follow the following algorithm:

- Box in position P and warmed up to 30-100 degrees C;

— The engine is started;

— The brake pedal is depressed for the duration of the entire procedure.

If all conditions are met, you must connect Vag Com. The adaptation is done as follows:

1. In the program interface we find the item Basic automatic transmission settings.
2. Select the Gear Clutch Settings item, press “Go!”. The box will begin to make sounds, and the numbers in the program will change. You have to wait until it stops.
3. Select the Gear Shift Points item, click Go. Similar to point 2, we are waiting.
4. We select the item Clutch adaptation, the actions are similar to point 2. Then we do everything similarly to point 2.
5. Item Basic settings.
6. Item Pressure adaptation.
7. Item With shift paddles installed.
8. Item ESP and Cruise.
9. Click Done.
10. We turn off the ignition.
11. We wait a few seconds.
12. We turn on the ignition.
13. We look for errors, if necessary, delete them.
14. Exit the controller.
15. Without using cruise control, we perform a test drive.
16. Get off their Vag Com. Adaptation completed.

Replacing the mechatronics unit will require a new firmware. Fortunately, this is easy to do. DSG 6 mechatronics and DSG 7 mechatronics control units are easily flashed using this program.

We repair DSG

If there are jerks and kicks during the operation of the box, extraneous noise, then it's time to go for diagnostics. DSG repair is quite complicated

Dual clutch on robotic gearboxes, despite all its advantages, is a consumable item. No matter "wet" type of clutch or "dry". With aggressive use, dual clutches hardly live up to 40,000, it is better to change it as an assembly at the first symptoms.

The mechatronics unit is very delicate, requiring careful handling, warming up and not loving overheating. One of its weak points is the cooling system pipes made of plastic. From temperature changes and vibration, they can burst or crack, which will lead to coolant leaks and overheating of the box. Moreover, the gearbox can overheat from prolonged standing at a traffic light at speed.

The heat exchanger unit can generally depressurize and mix oils with antifreeze.

The roller bearings of the output shafts can run less than 50,000 if they have been subjected to heavy loads. When a gear tooth breaks, a characteristic knock will appear, which is also not uncommon. Also, extraneous noise in the box may indicate wear on the input shaft bearing, other bearings of the mechanical part, and the box differential. When the engine speed increases, stops, turns, the noise usually increases.

Failure of the electric pump of the control unit will immobilize the machine. If some electrical circuit in it is sour, this behavior may be periodic. A faulty control unit can periodically throw the box into emergency mode.

Worn solenoids can lead to jerky gear changes, the self-diagnostic system will not see problems. If you do not pay attention to such signs, then, most likely, soon the box will completely “stand up”. Its repair is not cheap, and in Russia it has not yet been mastered very well. It can even be difficult to find a suitable service with specialists who will undertake such work. Before buying a car with a robot, consider whether all its advantages are worth such repair problems.

The DSG box, like all similar boxes, is a fairly early development and they are just beginning to be modernized and worked out. The manufacturer's warranty still covers all possible troubles. Until the moment when eternal robot boxes appear, as the American and Japanese millionaire automatic transmissions once appeared, it will be a long time, maybe another 2-3 generations of these gearboxes.

The DSG robotic gearbox (English spelling Direct Shift Gearbox, German - DirektSchaltGetriebe), despite all the claims, is currently the most advanced automated gearbox installed on mass car models.

The DSG box provides gear shifting without interrupting the power flow, which significantly improves its consumer qualities compared to other "robots". These qualities include the best acceleration dynamics and fuel economy (the engine does not idle).

Continuous transmission of torque from the engine to the drive wheels is achieved through the use of two clutches and their corresponding two rows of gears. The DSG transmission has six-speed and seven-speed designs. A seven-speed gearbox (torque up to 250 Nm) is installed on cars B, C and some D class models. A six-speed gearbox transmits torque up to 350 Nm and is installed on more powerful machines.

The design of the DSG gearbox includes a dual mass flywheel, dual clutch, two rows of gears, final drive, differential and control system. Structural elements are placed in the body (crankcase) of the box.

The double clutch provides torque transmission to the first and second rows of gears. On a six-speed gearbox, the clutch includes a drive disk connected through the input hub to the flywheel, and two friction multi-plate clutches connected through the main hub to the gear rows. The seven-speed gearbox has two conventional friction clutches.

On a six-speed gearbox, a wet-type double clutch, i.e. constantly in oil. The oil provides lubrication and simultaneous cooling of the discs, which significantly increases the clutch life.

The seven-speed gearbox is equipped with a dry clutch, which can significantly reduce the amount of oil refilled (from 6.5 liters to 1.7 liters), reduce energy costs and increase the fuel efficiency of the engine. For the same purpose, the hydraulically driven oil pump on the seven-speed gearbox has been replaced with a more economical electric pump. On the other hand, dry clutches are subject to more wear.

The first row of the gearbox provides odd gears and reverse, the second row is responsible for even gears. Each of the gear rows is a primary and secondary shaft with gear blocks. Primary shafts are located coaxially, while the primary shaft of the second row is made hollow and put on the primary shaft of the first row.

The gears on the input shafts are rigidly connected to the shaft. The pinion gears rotate freely. In this case, the gears of the primary and secondary shafts are in constant engagement. Synchronizers are located between the gears of the secondary shaft, which carry out the inclusion of a specific gear. To perform a reverse movement in the gearbox, an intermediate shaft with a reverse gear is provided. The drive gears of the final drive are also located on the secondary shafts.

Direct control of the clutch and gear shifting is provided by the control system. It includes input sensors, an electronic control unit and an electro-hydraulic unit as actuators.

Electronic and electro-hydraulic control units, as well as almost all input sensors, are combined into a single module called Mechatronic. The control module is located directly in the gearbox housing.

The input sensors monitor the input and output speed of the transmission, oil pressure and temperature, and the position of the gear shift forks. The electronic control unit, based on the signals from the sensors, implements the control algorithm for the electro-hydraulic unit embedded in it.

The electro-hydraulic control unit controls the transmission's hydraulic control circuit. It includes control spools, solenoid valves and pressure control valves, multiplexer.

The valve spools are actuated by the selector lever. Solenoid valves carry out gear shifting. Pressure control valves ensure the operation of the friction clutches. Solenoid valves and pressure control valves are the actuators of the transmission control system.

The gearbox uses a multiplexer device that allows you to control eight gear shift hydraulic cylinders using only four solenoid valves. In the initial position of the multiplexer, some hydraulic cylinders operate, in the working position, others, while in both modes there are common solenoid valves.

The principle of operation of the DSG transmission is to sequentially engage the gears of both rows. In this case, during the operation of one gear, the next gear is already selected and ready to be switched on.

Nowadays, you can find vehicles of various designs, and not all of their mechanisms are distinguished by flawless operation. This article will focus on a rather unusual, robotic gearbox - DSG 7. Anyone who has already encountered it or is simply interested in various innovations in the automotive world will certainly be interested in receiving additional information regarding this issue.

1. What is a DSG gearbox

The abbreviation "DSG" stands for Direct Schalt Getrieb and literally means "direct shift box". In fact, this is only one of many types of preselective robotic gearboxes equipped with two clutches. In fact, the “robot” is the same, only the control in it is automated.

When a gear shift is required, the on-board computer sends a special “command” to the actuators, and they disconnect the clutch disc from the master, thereby breaking the connection between the power unit and the box. As a result, after the movement of the shafts with gears, the disks are connected back, and the process of transmitting torque is resumed.

It should be noted that the computer does not always cope with this task quickly, and in most cases it takes more time than the driver would need. Therefore, if you are a fan of dynamic driving, then it is better to buy a vehicle with a conventional manual transmission.

However, the dual clutch box is somewhat different from the typical "robots". It was invented by the French engineer A. Kegresse, who until the First World War worked in the personal garage of Nicholas II. By the way, it was he who invented the caterpillar-wheel engine for the royal Packard.

True, at the end of the 30s, when the principle of operation of the double clutch was described in detail by Kegresse, existing technologies did not yet allow the construction of a prototype, and this possibility was safely forgotten until the beginning of the 80s. The “novelty” was tested on Ford cars (model Fiesta and Ranger) and Peugeot 205, after which it was put on racing Audi and Porsche.

2. What is the difference between DSG 6 and DSG 7

There are two types of DSG direct shift gearboxes - DSG 6 and DSG 7. The six-speed DSG 6 was the first to appear in 2003, in which the dual clutch worked in an oil bath (“wet” version). Such a large amount of oil turned out to be a significant problem, because it was because of it that the engine lost its power. This nuance was the impetus for the creation of a more advanced version of the gearbox, which is the DSG 7, introduced by Volkswagen in 2008.

This design has reduced the amount of gear oil used, as it is now only used for lubrication and not for cooling the clutch. As a result, efficiency increases and fuel consumption decreases. However, the use of a dry clutch led to other problems, which we will talk about a little later. In general, the only thing that distinguishes the 7th model from the 6th (apart from the difference in the amount of oil) is the presence of 7th gear.

The DSG-7 gearbox is installed on middle-class cars that are not so demanding in terms of speed and are more designed for a quiet and calm ride.

3. Classic DSG 7 problems

There are many problems that you may encounter when using the classic dry DSG 7 gearbox. Some of the most common options include:

1. The appearance of machine vibration when shifting gears from first to second and vice versa. Cause: Clutch discs close too hard and it feels like you're dropping the clutch (remember this moment when driving a car with a manual transmission). In this case, an error occurs in the mechatronics unit and is eliminated by flashing or replacing it.

2. The occurrence of vibrations in 2nd gear when moving at low speeds. Here the source of the problem should be sought in the absence of a torsional vibration damper on the second clutch. Volkswagen AG engineers thought that it would be enough to install a damper on the first clutch, because it is the most loaded. In addition, the area of ​​its clutch is larger than the area of ​​the clutch of the second clutch.

After the company LUK (which was responsible for the creation of the DSG-7) nevertheless released a clutch with a modified clutch material, the vibrations did decrease somewhat, but still did not completely disappear. VAG specialists are trying to fix this problem through software updates, but one mechatronics specialist will not be able to solve the “disease” of the entire structure. Simply put, rattling will accompany the work of the DSG-7 until the next box model is released.

3. Knocking in the gearbox when driving at low speeds is another common problem with this type of gearbox. The official explanation for this problem is based on the fact that the gearbox contains a large number of tightly packed parts, and under certain conditions, due to heavily loaded parts and gears, vibration may occur. Given that the amount of transmission fluid in this model is not very large, the transmission of sounds from the gearbox to the outside is more intense.

True, the appearance of such noise only affects the personal comfort of the driver and passengers, without affecting the performance of the gearbox and its resource. This "inconvenience" is not even considered a defect, because of which the employees of specialized workshops will not be able to help you. Therefore, before buying a vehicle with a DSG 7 gearbox, decide whether you can “survive” this noise or not.

4. Jolts at the beginning of the movement and when switching to the modes "D", "S", "M". In this case, the set of reasons for this behavior of the machine is quite extensive. For example, a malfunction can be hidden both in the clutch unit and in mechatronics or in the engine-gearbox assembly. Be that as it may, it is better to check the vehicle for which such a malfunction was noticed in a car service.

5. Breakdown of mechatronics can also have a variety of reasons. However, most often the culprit is the software version and the mode of operation of the car. Earlier models were much more likely to suffer from mechatronics failures caused by software errors.

Today, most of the problems have been eliminated with the help of constant updating of the "brains", as a result of which the electronics began to behave more obediently, although they are still not immune from operational errors. For example, a hard start with the brake pressed can easily lead to a complete breakdown of the box with a “dry” clutch.

As you can see, all of these problems lie in the complex design of the DSG 7 gearbox. It turns out that the specialists of the Volkswagen AG concern sought to create the perfect gearbox, and now they are paying for mistakes with annual transmission upgrades.

4. Car models with a problematic DSG 7 box

A fairly large number of cars loved by everyone were produced with a problematic DSG 7 gearbox. One has only to recall the Škoda Octavia, VW Golf or Audi A3 of 2014. However, this is still far from all contenders for the appearance of the above problems. Delving into the essence of the issue, one cannot help but recall other cars that were “lucky” to become owners of this gearbox.

Among the vehicles of the brand Audi models stand out in this respect. TT (2010-2014), A1 (2010-2014), A3 (2008-2014), A4 (2007-2014), S4 (2008-2014) .), A5 (2007-2014), A6 (2011-2014), A7 (2010-2014), Q5 (2008-2014) and R8 (2012 -2014 onwards). Concern SEAT installed DSG 7 on the model Ibiza (2008-2014), León (2005-2014) and Altea (2009-2014).

The creators of some models did not differ either SKODA. In particular, DSG 7 operates on Škoda Octavia (2004-2014), Škoda Superb (2008-2014) and Škoda Yeti (2009-2014). However, most of these boxes are installed on the products of the concern. VOLKSWAGEN:Polo (hatchback 2009-2014), Golf (2009-2014), Jetta (2005-2014), Touran (2010-2014), New Beetle (2013- 2014 MY), Passat (2005-2014 MY), Passat CC (2008-2014 MY), Sharan (2010-2014 MY), Scirocco (2009-2014 MY) ), Tiguan (2011-2014), Caddy (2010-2014).

Of course, for each specific model, you can choose your own solution to the problems of the DSG 7 gearbox, but sometimes it’s easier to just replace it with a more suitable, alternative gearbox option. For example, for a Škoda Octavia with a volume of 1.4 liters, 1.4 (140) 6MT is well suited, and for an Audi A3 (volume of 1.8 liters), if necessary, you can pick up 2.0 (143) DSG6.

Despite the possible disadvantages, many of the listed car models have been successfully operated for more than one year, and problems with the gearbox do not bother their owners. It is likely that, in your case, you will not have to figure out how to solve the above problems for a long time, but, nevertheless, it is better to know about this possibility in advance. Naturally, before buying a car with this system, it is worth weighing all the pros and cons well, and it is better to additionally consult with a knowledgeable person.

When they say DirektSchaltGetriebe, for some reason, the dark times of the Third Reich and the Ahnenerbe department, the Higher Unknowns and other occult nonsense of the secret SS department are immediately remembered. In fact, everything is much more harmless. The higher unknowns are fundamentally different synchronized shift gearboxes, the name of which in English interpretation sounds more soothing - Direct Shift Gearbox, DSG. This is a new word in automotive engineering, it was written in the tablets of history by Volkswagen AG and was the first in the world to launch mass production.

Higher Unknowns, or what is it - DSG gearbox?

In the photo - Direct Shift Gearbox (DSG) or a new word in automotive engineering

With all the claims and quibbles about this design, this is the most advanced gearbox on planet Earth. The highest stage in the evolution of transmission, unknown to many and terrible for competitors. Due to the high level of competition, perhaps, all the talk about its failure arises. The DSG gearbox has already raised its pen to sign the verdict on all existing automatic, CVT and manual transmissions. Why did the rest of the boxes annoy the engineers from Volkswagen so much?

A manual gearbox is a well-thought-out mechanism well adapted to modern powerful high-speed motors. With filigree use, it provides accurate and precise gear shifting, a fairly wide range of gear ratios, but one thing is bad in it - you need to constantly work with the lever, and catching the engine speed literally intuitively. Otherwise, with one inaccurate movement, one inaccurate throw of the clutch, the car twitches, comfort is lost, and most importantly - precious seconds and torque. The hydromechanical automaton, it seems, was called to solve these problems, but brought only new ones. Yes, the torque converter perfectly smooths out all the jerks when shifting gears, evens out the traction force, but the price of this comfort is the loss of a huge amount of power, excessive fuel consumption, as a result, the efficiency of this couple, engine and automatic transmission, falls to an unforgivably low level. High hopes were placed on a robotic transmission with an electric clutch and gear shift, but they did not materialize either in terms of comfort or power loss.

DSG Robotic Transmission Video

And the engineers of VW AG were not wiser for a long time. All the gearbox was missing for optimal performance was one more gearbox and one more clutch. DirektSchaltGetriebe, DSG, works exactly like this. While acceleration is in progress and the odd first gear is engaged, the even second gear is also already engaged, but not connected to the crankshaft flywheel. The transmission, in other words, is "pre-selected", which is why such boxes are also called preselective. As soon as the moment comes to shift to an increased, even, gear, it is enough to simply open one clutch and close the other. It takes a fraction of a second, there is no break in the flow of power, the car practically does not feel any jerks and drops in acceleration dynamics, and this is how this was achieved constructively.

The device and problems of the DSG gearbox

DirektSchaltGetriebe is a dual circuit gearbox, which means that it has as many as 5 shafts and as many as 2 clutches. Clutches can be wet and dry, it depends on which engine the gearbox is bolted to and how many steps it has. Such a box can also be controlled manually - using the Triptronic system or paddle shifters, as on most sports cars. In terms of smooth operation, DSG is no different from automatic transmission, and in terms of acceleration dynamics it is not inferior to mechanics with the most experienced driver. And this is an indisputable fact. A lot of tests and comparative tests were carried out, during which the DSG box showed its superiority over the mechanics both on the sports track and in the frequency of gas station arrivals. The difference in fuel consumption during the operation of the VW Golf R32 with both gearboxes, manual and DSG, was no less than 1.3 liters per hundred. And all due to saving torque, and the same Golf R32 accelerates to hundreds in 6.4 s, and with mechanics - in 6.6 s, but at maximum speed the difference in the gearbox is not visible - 247 km / h.

There are two types of DSG boxes - with wet and dry clutches. Wet clutch has its disadvantages in that a certain amount of engine energy is spent on overcoming the resistance of the oil bath. As a rule, this is a six-speed DSG, and it is installed on cars with higher torque and, accordingly, more powerful ones. DSG6 is installed on Volkswagen and Skoda Octavia with torque above 250 Nm and up to 350 Nm. Only on powerful and large engines does a six-speed DSG make sense. In 2008, Volkswagen introduced the seven-speed DSG7 for lower power and smaller displacement engines. Since then, it has become possible to install these boxes on small-capacity cars with a volume of 1200, 1400 cm³. The 7-speed transmission has a dry clutch, so there is no loss of power due to the oil bath. After 2008, the design of the six-speed boxes also changed. An electric drive was used on the oil pump of the hydraulic system, which made it possible to increase the efficiency of the engine by a few percent.

Problems with the DSG box are noted, judging by the reviews, only when the maintenance regulations, oil changes, and operation contrary to the instructions are not followed. Repair of such a box will not be cheaper than a machine. In the cold season, this box requires warming up, otherwise there may be jolts and jerks when switching from first to second gear until the box warms up. Another disadvantage of the 7-speed DSG is that it is not used with powerful engines. Maximum - 122-horsepower 1.4 TSI with two supercharged or diesel 1.9 TDI with 109 forces. Nevertheless, no one deprives you of the choice - you can buy the same Passat, Golf, Octavia, or Audi as with traditional mechanics, with a hydromechanical automatic machine, or with the Higher Unknown DirektSchaltGetriebe, preselective DSG gearboxes.

• News
• Workshop

Traffic police fines to be used for road construction

The draft of the relevant amendments to the Budget Code was developed by the Ministry of Transport of the Russian Federation. According to Izvestia, thanks to the changes, the subjects of the federation will be required to transfer road payments and fines to local road funds. The Minister of Transport of the Russian Federation Maxim Sokolov announced the preparation of an appropriate initiative back in April. The project involves 10 types of payments directly...

Forecasters advised motorists to change tires

The head of the Hydrometeorological Center of Russia, Roman Vilfand, spoke about this at a press conference, the Moskva agency reports. According to weather forecasts, the next five days in the capital will be cooler than the long-term average. So, on Saturday night the temperature will drop to minus 7 degrees. In general, the lag of the average daily temperature from the climatic norm will be 2-3 ...

A new dedicated lane will appear in the center of Moscow

The new leased line is planned to be launched on September 1, 2016. This is with reference to the adviser to the head of the Moscow Department of Transport and Road Infrastructure Development Alexei Mityaev, the RIAMO agency reports. Mityaev also clarified that the creation of a new lane for public transport is carried out as part of the My Street improvement program. He also added that today in the system...

From the new Volkswagen Polo will make a convertible crossover

This spring, Volkswagen showed the T-Cross Breeze concept at the Geneva Motor Show, moreover, the leadership of the German concern noted at length that the convertible crossover could well become serial if the public shows due interest in this kind of model. However, judging by the images published by the Spanish edition of Motor, the German bosses have long decided ...

The new Kia sedan will be called the Stinger

Five years ago at the Frankfurt Motor Show, Kia unveiled the Kia GT concept sedan. True, the Koreans themselves called it a four-door sports coupe and hinted that this car could become a more affordable alternative to the Mercedes-Benz CLS and Audi A7. And now, five years later, the Kia GT concept car has transformed into the Kia Stinger. Judging by the photo...

In the Stavropol region again allowed to use hand-held radar

This was told by the head of the UGIBDD for the Stavropol Territory, Alexei Safonov, RIA Novosti reports. The head of the local traffic police said that 30 violations of the speed limit were recorded in 1.5 hours of work. At the same time, those drivers who exceed the permitted speed by 40 km / h and above are identified. At the same time, Safonov proposed introducing criminal liability ...

GMC SUV turned into a sports car

Hennessey Performance has always been famous for its ability to generously add additional horses to a “pumped” car, but this time the Americans were clearly modest. GMC Yukon Denali could turn into a real monster, fortunately, that the 6.2-liter "eight" allows you to do this, but the mechanics of Hennessey limited themselves to a rather modest "bonus", increasing the engine power ...

In St. Petersburg, a car was stolen without an engine and a roof

According to Fontanka.ru, a businessman turned to the police and said that a green GAZ M-20 Pobeda, which was produced back in 1957 and had Soviet numbers, had been stolen from the courtyard of his house on Energetikov Avenue. According to the victim, the car did not have a motor with a roof at all and was intended for restoration. Who needs a car...

Russian assembly of Mazda: now they will also make motors

Recall that the production of Mazda cars at the facilities of the Mazda Sollers JV in Vladivostok started in the fall of 2012. The Mazda CX-5 crossover was the first model that the plant mastered, and then the Mazda 6 sedans were put on the conveyor. At the end of 2015, 24,185 cars were produced. Now Mazda Sollers Manufacturing LLC...

The traffic police published new exam tickets

However, the traffic police decided today to publish on its website new examination tickets for categories "A", "B", "M" and subcategories "A1", "B1". Recall that the main change that awaits driver candidates from September 1, 2016 concerns the fact that the theoretical exam will become more difficult (and, therefore, you need to learn tickets more carefully). If now...

Throughout the history of the automotive industry, designers have always liked to single out a few unique in terms of characteristics and capabilities from the general mass of production models. At the present time, this approach to the design of cars has been preserved. To this day, many global auto giants and small companies strive to ...

What cars in 2018-2019 are most often bought in Russia

The number of cars on the roads of the Russian Federation is constantly growing - a fact that is confirmed by the annual study of sales of new and used models. So, based on the results of the study, which can answer the question of what cars are bought in Russia, for the first two months of 2017...

Which sedan to choose: Camry, Mazda6, Accord, Malibu or Optima

Powerful story The name "Chevrolet" is the very history of the formation of American cars. The name "Malibu" beckons with its beaches, where numerous films and television series were filmed. Nevertheless, from the first minutes in the car "Chevrolet Malibu" one can feel the prose of life. Pretty simple stuff...

A 6 or 7 speed DSG box 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 device and principle of operation of a robotic gearbox.

[ Hide ]

The device and technical details of DSG boxes

The DSG robotic gearbox is a dual-clutch assembly. Such gearboxes are installed on cars manufactured in 2013, 2014, 2015, 2016 produced by the VAG concern. The driver of the car selects speeds, and the transmission control module automatically controls the clutch and transmits the appropriate commands for gear shifting. 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 in 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. In such machines, a double "wet" clutch is used. It always works in oil, which is used to lubricate the friction elements and cool the discs. This helps to increase the service life of the transmission unit. This gearbox is not the last model of Volkswagen robotic boxes, however, it is considered one of the most powerful. The amount of torque varies around 350 Nm.
2. Seven-speed. In such gearboxes, a “dry” clutch is used, because of this, the unit needs three times less lubricant. Unlike six-speed gearboxes, which used hydraulically driven oil pumps, seven-speed gearboxes are equipped with electrical devices. Due to this, energy costs are reduced and the fuel efficiency of the power unit is increased. But the clutch life is lower. Seven-speed transmissions began to be put on cars three years after the release of DSG 6 and they are intended for more budget car models. The total weight of the box varies around 70 kg. The gearbox torque is no more than 250 Nm. The main feature of this type of transmission is that it is equipped with two friction clutches that do not operate in an oil bath. Thanks to this, the engineers were able to achieve the highest efficiency of the unit.

Principle of operation

The main catalyst that provides the transmission of torque to both rows of gears is the automatic transmission's dual clutch. Thanks to him, the master disk is launched. This element is connected to the friction clutches, as well as the flywheel through a special hub with another mounted flywheel. Thanks to the hub, both rows of gears are combined. The first works only with odd speeds and reverse gear, and the second works exclusively with even ones. Each row of the transmission unit functions in conjunction, representing 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;
• an electronic component used to control the unit through a computer utility;
• hydraulic device;
• mechanisms and units designed to execute commands given 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 the electronic components, are located in one unit - mechatronics. The controllers to which the impulse is transmitted from other machine systems are installed in the same block. Input regulators are used to read information about how rotation is performed at the output and input of the transmission assembly. Thanks to them, the diagnosis of the temperature of the lubricant, the pressure in the system, as well as the correct location of the gearbox forks are carried out. The control module receives data from the controllers, as a result of which the system starts one of the cycles stored in the program memory of the central processor.

A hydraulic or electrical device is used to adjust the circuit of the gearbox.

The main components of this system:

• regulating and solenoid valves, the former are used to control the magnitude of the pressure;
• distributing spools;
• multiplexer.

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

User Yaroslav Efremov in his video spoke about the main malfunctions that are typical for robotic boxes.

Main malfunctions

In the operation of even the most reliable automatic transmission, breakdowns and errors can occur, which lead to the repair of units.

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

1. Clutch failure due to rapid wear. The main symptom of such a problem is the periodic loss of reverse speed, and when the driver engages even-numbered gears, the car starts to move with jerks and jerks. Since the box is controlled by the central processor, the unit can automatically go into emergency operation. In this case, one of the rows of speeds will not turn on. An error will remain in the memory of the central processor, which will make it possible to identify the malfunction by computer diagnostics. To fix the breakdown, it will be necessary to replace the friction clutch assembly or individual disks of this assembly. Usually, the change of individual elements is relevant if the vehicle mileage is not more than 150 thousand km. When performing repair work, adjustment using a diagnostic stand is necessary. Also, the clutch of the box must be adapted to the car while driving.
2. Failure of mechatronics solenoids as a result of wear. We are talking about elements designed to regulate pressure. Breakage of the solenoids causes jerks when switching speeds. The unit can continue to work in this mode, since the central processor does not see this problem and does not leave an error in its memory. To get rid of the malfunction, you will need to replace the solenoids or install a new mechatronic on the gearbox.
3. The mechatronics control module began to work intermittently. Such problems are clearly manifested during a cold start of the car engine. The transmission unit starts to work in emergency mode, but after restarting the internal combustion engine, it continues to function normally. The main feature of such a problem is that the gearbox can 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 the central processor. In some cases, the control module must be repaired.
4. Failure of the bearing elements, the mechanical component of the unit on the input shaft as a result of wear. The differential of the system may also break. The main "symptom" of such a 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 is out of order, then the noise will also appear when entering the turn. Sometimes it appears during a sharp acceleration or braking of the car. Such malfunctions are dangerous for the transmission unit with serious consequences. 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 properly and break down over time. In this case, clutch wear will be faster. As a result, a malfunction will lead to the need to overhaul the gearbox. 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 in the secondary market.
5. Another problem is the failure of the dual-mass flywheel as a result of wear. The first sign of a problem is the appearance of noise and clanging when the engine is idling. Also, sounds appear when the power unit is started and stopped. To get rid of the problem, the flywheel changes.

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

Troubleshooting

In Audi, Seat and other VAG vehicles, almost all malfunctions are mechanical in nature. If the moving components and assemblies of the unit wear out, they must be replaced. Please note that the elements wear out much faster when the driver increases speed sharply and brakes just as sharply or is often idle in traffic jams. Repair work related to the central processor is 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 boxes, it is not necessary to change the oil, since it is filled for the entire service life of the machine. In all other transmission units, lubricant is poured for 60 thousand kilometers.

You need to change the oil in such cases:

1. If there are problems in the operation of the transmission unit. The box began to kick and push when shifting gears, and all its components and mechanisms are intact. Such problems indicate the use of low-quality transmission fluid.
2. If the oil has turned black and a deposit has appeared in it in the form of metal chips and other wear products. It is necessary to identify the malfunction and remove it, and then start flushing the unit and replacing the lubricant. Wear products will eventually 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 modes of the gearbox with a lever, the brake pedal should be clamped to the stop. The design of the robotic transmission is such that if the driver slightly presses the brake, the clutch discs will not be able to fully open, which leads to their rapid wear.
2. Try to use neutral speed as little as possible. If you are in a traffic jam or plan to stop for no longer than one minute, then it is better to coast. At the same time, 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. Cars equipped with robotic gearboxes cannot be used for towing. The transmission is designed for a certain weight of the car, so it is not allowed to take other cars in tow or use a trailer on such cars. SUVs may be an exception. Their mass is quite large, so the load on the box will not be so critical.
4. Never skid by car, we are talking about a sharp start of movement with wheel slip.
5. If you move the gear selector to the park position, you do not need to release the brake pedal. You should raise the "handbrake" to prevent failure of the limiter if the car starts to roll back.
6. All positions of the gearbox selector must be turned on smoothly, observing a second delay. Please note that electronics need a certain amount of time to adjust to a particular mode.

These rules are similar to the control of 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 reverse without a pause at neutral speed. On machines with a gun, you can move with a slip. This is harmful to the transmission unit as a whole, but not as critical as for robotic gearboxes.

If you get into a snowdrift or get stuck in the mud and you can’t get out of the obstacle on your own, then when you pull the car out of the snowdrift, the gearbox selector should be shifted to neutral. When towing the machine, remember that the speed of movement should be low. There is also a certain distance that a vehicle is allowed to be towed. This data is usually indicated on the front pillar of the car.

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

Pros and cons of "robots"

Consider the advantages of robotic transmissions:

1. In such gearboxes, gear changes are almost instantaneous. Thanks to this, the driver does not lose precious seconds when overtaking or performing other maneuvers on the track.
2. All manufacturers of cars on which robotic gearboxes are installed claim fuel savings. This is a debatable advantage. Perhaps such cars do consume less fuel, but only in comparison with 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 repair cost. 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 when it comes to new cars.
3. The process of changing transmission fluid is complicated. Changing the lubricant in garage conditions is problematic due to the design features of the unit. If you contact a service station for help, you will have to pay a round sum for a replacement.
4. Robotic transmissions are negatively related to the aggressive style of movement. The nodes and elements of such gearboxes wear out faster with a sharp start and braking.
5. The cost of vehicles with a robotic gearbox is higher than cars with automatic or manual transmission.