What is a DSG gearbox - the advantages and disadvantages of a double-clutch gearbox. Features of DSG What is DSG in cars

The DSG robotic transmission is the main gearbox for cars included in VAG (Volkswagen, Seat, Skoda can also include Audi, although the DSG is called S-tronic there). Let us remind you that today there are three types of DSG - two with a wet clutch and one with a dry clutch. The first type includes the six-speed DQ250 and seven-speed DQ500, the second type includes the DQ200, which has received a dubious reputation for reliability.

In our article today, we would like to talk in detail about DSG 6, discuss its reliability, talk about cars that are equipped with it in 2018, we will ask the owners for their opinion, what do they think about the robot, its pros and cons.

Which cars are equipped with DSG-6

First of all, let's get acquainted with the list of new cars that are equipped with a six-speed DSG with a wet clutch that are sold in Russia in 2018.

A Czech brand, which currently belongs to a German concern, as a result of which all the technical components of the cars are completely similar to Volkswagen. A robot with an oil bath clutch is installed mainly on all-wheel drive or powerful models, which include

• Kodiaq– on the crossover the robot is available with a 1.4 liter gasoline engine 150 hp And all-wheel drive:
• Octavia And Octavia Combi– in both body types, the DQ250 is available with the model’s top-of-the-line 1.8 liter petrol engine producing 180 hp. and all-wheel drive
• Octavia Scout- essentially the same station wagon, only with increased ground clearance and the presence of plastic protection around the body
• Octavia RS And Octavia Combi RS– this sports car is equipped with a 2.0 liter petrol turbo engine producing 230 hp. and front-wheel drive
• Superb And Superb Combi– here the six-speed gearbox is installed on a front-wheel drive version with a 2.0 liter engine producing 220 hp. and an all-wheel drive version with an engine of the same size, but with a power of 280 hp.
• Yeti– on this model, the robot is only available with all-wheel drive and a 1.8 liter gasoline engine with 152 hp.

Volkswagen

The German automaker has a wide list of models with DSG 6 that can be purchased in 2018 in Russia, these include:

• Caddy- a compact van, which is not so often seen on the roads of our country, the reason for this is the rather high cost, although the car is excellent. On this model, a 6-speed gearbox is available with a 2.0 liter 140 horsepower diesel engine and all-wheel drive.
• Caddy Maxi– as you can guess from the name, this is an enlarged version of the German compact van; the robot here is also available with a 2.0 diesel engine and all-wheel drive.
• Passat and Passat Variant- unfortunately until Russian market Only variants with front-wheel drive and 2.0 arrived liter diesel 150 hp
• Tiguan– the second generation of the popular crossover has a wider list of variations compared to the first generation, on which DSG-6 is installed. This is mainly a 1.4 liter engine with power from 125 to 150 hp, and there is also a choice of front-wheel drive or all-wheel drive.

Advantages and disadvantages

Let's start with the advantages:

• gear shift speed. The robotic transmission clicks through gears much faster than the average driver. There are a huge number of videos on the Internet where they test the acceleration of identical cars that differ only in gearboxes, and as practice shows, a car with a DSG always accelerates faster than a car with a manual transmission;
• The second advantage of a modern gearbox can be considered smooth acceleration, due to the lack of sensation from shifting gears:
• Fuel consumption is significantly lower than that of a standard automatic, and the manual is inferior, although it all depends on the driver’s experience.

Disadvantages that owners most often complain about in 2018

• some owners are not happy with the fact that in a traffic jam they have to switch the selector to position N (neutral):
• rumors of insecurity. With the excellent potential of the car, sometimes you want to press the gas pedal and leave the traffic light with a whistle, but sometimes you are afraid for the transmission, because. to prolong its life, it is better to start smoothly, and then, starting from second gear, you can press down on the gas;
• the cost of repairs and components compared to mechanics.

Reliability, how are things going in 2018?

The issue of reliability is perhaps the main fear that stops many from purchasing VAG cars. The issue of reliability and negative reviews about the robot began to appear on forums and on the Internet only after the appearance on the market of the seven-speed DSG-7 robot with a dry clutch, while on the market for a long time Cars were sold with a “wet” one, which did not cause any complaints. Practice shows that the DQ250 is capable of traveling about 150,000 km without any problems, provided correct operation and proper maintenance. Car owners buying new cars don’t have to worry about anything, because... The warranty will allow defects to be corrected without question with the help of the dealer. But when buying a car on the secondary market, it is better to diagnose the DSG 6 box, and then service it by replacing consumables and oil.

Reliability is evidenced by the fact that even on sports models, such as the Skoda Octavia RS, the transmission does not break down even on runs of 100,000 km. And this is worth a lot, because... I use cars of this kind quite harshly and often go to the track.

Owner reviews 2018

We talked to the owners of cars equipped with this gearbox and this is what we found out.

Vitaly Volkswagen owner Passat CC

I really like the way it looks this car. Before that, I owned the pre-restyling version of the Passat SS with a 1.8 liter engine and a seven-speed automatic transmission, but unfortunately I had to sell it because . I decided to buy a restyled version with a 2.0 liter engine and a “wet” DSG, which I don’t regret, because Over three years of operation, the box has not caused any problems.

Toha Skoda owner Octavia RS A7

I was choosing between an Audi A4 with a 2.0 liter engine, Volkswagen Golf GTI and the Octavia RS itself, I settled on the latter due to the ratio of price and size of the car. What can I say, I’m completely satisfied with the car and the gearbox, I drove it stock for a year, then did Stage 1. At the moment the mileage is 42,000 km, I’m thinking about doing Stage 2.

Kirill (Bravo_77) owner of Skoda Yeti

The second car was not bought new for driving. I was looking for a Seat Freetrack for a long time. Due to the presence of all-wheel drive and the correct DSG, but not finding a copy in acceptable condition for a reasonable price, I decided to take the Yeti, although it is slightly inferior in terms of engine capacity, but it looks much better in design. At the moment the car has Stage 3, more than 320 hp. and a reinforced transmission. I don’t regret caring, I’ve been pounding it constantly since lunch, and I change the oil in the gearbox every 15,000 km, using Vagov oil. At the moment, the Karabas has a mileage of 78,000 km and is holding up confidently.

Ilya Alexandrovich owner of Volkswagen Tiguan

The Tiguan was bought new from Rolf, I can say that I liked the car’s appearance, and the interior has a nice design plus a lot of space. Of course, I wanted to take a 2.0 liter with a seven-speed robot, which is installed on Audi, but unfortunately finances allowed only 1.4 150 horsepower and DSG 6. At the moment, the mileage is 17,400 km and this is what I can say, thanks to the quick operation of the gearbox and turbocharging, the engine’s low volume is not It feels like it’s enough for city driving. Regarding the gearbox, I can say the following - the gears switch quickly and smoothly, before that I had an Outlander with a CVT and a Camry with an automatic, so the DSG robot impressed me more, so in the future if I choose a new car, it will definitely be equipped with a DSG .

We hope in this article we were able to answer all your questions about reliability, service life and the pros and cons of the gearbox, and also give an answer - is it worth buying a car equipped with a DSG 6 robot in 2018.

Owner reviews are discussed in more detail in our next article.

What is DSG? In German, the abbreviation DSG stands for “direct gearbox” (Direkt Schalt Getriebe). It is often called “preselective,” that is, able to hold gears ready for the next shift.

The idea of ​​​​creating such a checkpoint belongs to the French inventor Adolphe Kegresse. In the 30s of the last century, an automotive engineer collaborated with Citroen. He proposed installing a unit with two clutches and hydromechanical control on the front-wheel drive Citroen Traction Avant. The new transmission has not received widespread use due to its complex design.

Volkswagen Favorite Hoff technical consultant Maxim Ponomarenko spoke about the advantages and features of the box.

How DSG works

The fundamental difference between a preselective automatic transmission and others is in two clutches that quickly change gears. In a manual or robotic gearbox, to change gears, the clutch disc is disconnected from the flywheel, the driver or robotic computer selects the desired “speed”, and after that the disc snaps into place. During this time, torque is not transmitted to the box and the car loses dynamics.

The DSG system allows you to get rid of power failures. The box is based on the work of two shafts located coaxially: the first is hollow, and the second is inside it. The engine is connected to each of them through its own, separate multi-disc clutch - also external and internal. The gears of the even gears (2nd, 4th, 6th) are fixed on the primary, that is, the outer shaft, and the odd gears are fixed on the inner shaft - 1st, 3rd, 5th and gears reverse.

When the car starts, the odd-numbered disk is pressed against the rotating flywheel, while the even-numbered “speed” disk is open. During acceleration, the computer unit of the box gives the command to prepare the second gear, so that at the moment it is turned on, it disconnects the odd-numbered row disk and immediately puts the even-numbered disk into operation. Tuned shift control ensures no loss of torque.

The DSG 6 robotic gearbox entered the Volkswagen assembly line in 2003. The double clutch on it operated in an oil bath, receiving the name “wet”. The oil in such a box takes away some of the power, increasing fuel consumption. In 2008, the German automaker introduced a seven-speed DSG 7 with a dry clutch.

DSG benefits

• DSG box due optimal modes turning on the required “speeds” allows you to reduce fuel consumption. Cars with it consume about 10% less fuel than cars with a conventional gearbox.
• A distinctive feature of all such transmissions is dynamic acceleration. To shift up a gear, the box needs only 8 ms; it does not have the effect of rubber traction as on hydromechanical automatic transmissions.
• You can drive the DSG in manual mode, that is, change gears manually.
• This automatic transmission is 20% lighter than a similar hydromechanical transmission.

Disadvantages of DSG

• The cost of automatic transmission affects the price of the car, significantly increasing it.
• Expensive oil changes (on a six-speed gearbox) every 60 thousand kilometers. The total volume is 6.5 liters.

The preselective box is installed on different models and brands united under the name of auto Volkswagen concern: Audi TT (A1, A3, A4, S4, A5, A7, A6, Q5, R8), SEAT Ibiza (León, Altea), Škoda Octavia (Superb, Yeti), Volkswagen Polo (Golf, Jetta, Touran, New Beetle , Passat, Passat CC, Sharan, Scirocco, Caddy).

Extended warranty for DSG

Among many car owners, the dubious glory of a dual-clutch transmission has gained a foothold. The name DSG itself has become a symbol of an unreliable design with costly repairs. In fact, Volkswagen has long ago taken control of the current situation. An important step towards quality control is a large-scale service campaign.

The concern provides an extended warranty for seven-speed gearboxes manufactured before January 1, 2014. According to representatives of the automaker, the indicated period corresponds to the appearance on the assembly line of a modernized transmission without typical problems last generation. Special service conditions are limited to 150 thousand mileage or 5 years of age of the mechanism. The service promotion includes replacement synthetic oil mineral - less aggressive towards electronic components. At the same time, the firmware of the automatic transmission control unit is updated. Detected malfunctions are eliminated free of charge - this applies to repairs, replacement of individual elements or the entire transmission.

In any case, you should not be afraid of the DSG abbreviation: with the proper level of service, it will not let you down, and in terms of the number of advantages, the “smart robot” outperforms the classic automatic transmission. And also DSG box will require less money for repairs compared to a conventional “automatic”.

What malfunctions are typical for DSG?

The most common problem is the jolts that accompany the movement when changing gears. The clutch discs close too quickly and the car jerks. The second known drawback is vibration at start, clanging, grinding and other extraneous noises during speed changes.

The main reason for the incorrect operation of the seven-speed transmission is its “dry” clutch. It wears out quickly due to harsh operating conditions in dense city traffic, with congestion at low speeds. Therefore, the question “how to operate DSG?” There is one obvious answer - to avoid the “gas-brake” mode, because the main enemy of the robot is a traffic jam.

Other problems include wear on shaft bushings, clutch release forks, broken solenoid contacts, dirt on sensors and oil in antifreeze.

How to determine a DSG malfunction when buying a used car?

• Some gears do not engage - the box “skips” them.
• Gear shifting is accompanied by shocks - the box “kicks”.
• There is a hum when driving.
• The car vibrates when starting.
• An inspection on the lift shows that oil is leaking from the box.

If you suspect that the box is not working correctly, you should order an additional check, or postpone this option.

Trust your choice to trusted used car sites. FAVORIT MOTORS is a team of experienced specialists, whose results are confirmed by first places in sales ratings. We sell prepared cars that have undergone detailed diagnostics. They have no hidden defects and a “transparent” legal history. You are purchasing a car that exactly meets your expectations, exactly suited to your needs.

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.

[Hide]

Design and technical details of DSG boxes

Robotic box automatic DSG 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 from robotic boxes Volkswagen, however, 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 costs and increases fuel efficiency 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.

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

The main components of this system:

• adjusting and solenoid valves, the first are used to control the pressure value;
• 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. There are eight of them in total, 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 characteristic of robotic boxes.

Basic faults

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 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. Because the box is driven 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 you to identify the malfunction using the computer diagnostics. To fix the damage, a replacement will be required. friction clutch assembled or individual disks of this unit. Usually, changing 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 manifest themselves during a cold start of the car engine. 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 can go into emergency mode unpredictably, without 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 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 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 reverse driving mode without a 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 machines actually 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 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. Changing lubricant in garage conditions is problematic due to 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.

The DSG transmission is a family of preselective gearboxes installed on Volkswagen AG vehicles.
The first DSG went into production in 2003, beginning to be serially installed on many models.
Since then, robotic gearboxes have been changed several times, and new modifications have appeared.

“ They differ from each other in the clutch design, layout relative to the engine, and are also designed to work in tandem with engines having different volumes, torque and type of fuel.

Today there are the following types of DSG:

• DSG6-02E/0D9 (DQ250)- the only version of the DSG with six stages.
  Equipped with a “wet” clutch, designed for front- and all-wheel drive vehicles, with a maximum torque of up to 350 Nm, and a volume of 1.4 - 3.2 liters;
• DSG7-0AM/0CW (DQ200) - the first generation of a seven-speed preselective.
  Dry type clutches. Designed for use with low-power internal combustion engines. Scope of application - front-wheel drive cars 1.2 -1.8 l, up to 250 Nm;
• DSG7-0BT/0BH (DQ500)- 7 steps, “wet” clutch.
  Installed on powerful models with front-wheel or all-wheel drive and a transverse engine. Adapted for transmitting high torque (up to 600 Nm);

DSG7-0B5 / 0CJ / 0CL / 0CK (DL501 / DL382) - also have seven gears and a “wet” clutch, but were developed specifically for cars with a longitudinal engine.

To find out what type of gearbox is installed on your car, just connect diagnostic tool and read identification data, or check by VIN code in the corresponding catalog.

According to its philosophy, DSG is a manual gearbox in which gear changes occur automatically. The driver has the opportunity to use the manual shift mode, but even in this case, gear changes are carried out by actuators by controlling electrical signals. This design does not imply a direct connection between the gearshift lever and the forks for changing the driven gears. Clutch operation is based on the same principle. The ICE flywheel is disconnected from the gearbox drive shaft by a servo drive at the command of the automatic transmission control unit.

A distinctive feature of the DSG gearbox is its dual clutch. Lightning-fast gear shifting speeds were achieved thanks to the fact that when a gear is engaged, the next gear is automatically engaged. For example, when you engage 1st gear, 2nd gear immediately follows. We can say that paired with manual transmission two separate clutch baskets operate. It will be difficult for you to understand the principle of operation of the DSG if you are unfamiliar with the car.

At the moment, there are two generations of robotic gearboxes from VW-Group. Each of them has its own characteristics, so the device DSG 6 and DSG 7 should be considered separately.

DQ250

Volkswagen AG launched DSG production in 2003. The gearbox was developed by the American company BorgWarner. According to the assurances of the designers, mechanical components can “digest” up to 350 Nm. This made it possible to find such a box on a car with an internal combustion engine volume of 1.6-3.2 liters. DQ250 is equipped with VW Golf, Scirocco Jetta, Passat, Sharan, Touran, as well as some Seat and Skoda models . Main components of automatic transmission:

To transmit torque from crankshaft A dual-mass flywheel is used. The main feature of the six-speed gearbox is a wet clutch, which in its design resembles a torque converter-type automatic transmission. Inside the housing there are 2 clutch packs, which consist of disks rigidly connected to the flywheel of the internal combustion engine, as well as friction disks meshed with the input shaft of the gearbox. When it is necessary to engage the gearbox shaft and flywheel, the discs are compressed under oil pressure. In mode idle move the discs rotate without engaging. The design uses a hydraulic oil pump, which supplies oil not only to the clutch, but also to the mechatronics actuators.

DSG 7

In 2008, the seven-speed DQ200, developed by Luk specialists, saw the light of day. The torque comfortable for an automatic transmission was limited to 250 Nm, so it is equipped with less powerful, lightweight cars with a transverse engine. Among the features of the device, one can highlight the clutch, which is arranged in one housing with a dual-mass flywheel, which is no longer combined with the oil bath inside the box. The operating principle of a dry clutch is identical to that used on cars with a manual transmission. This follows from the device:

Luk also replaced the hydraulic oil pump with an electrically driven system. This made it possible to reduce the oil filling volume by almost 4 times (1.7 liters versus 6.5 liters for DSG 6).

DQ500

The third generation of automatic transmission was developed by Volkswagen specialists. The manufacturer claims that it is capable of “holding” up to 600 Nm, which is why such gearboxes are installed on the Transporter 4×4, Tiguan and many other models from the VW-Group. The designers returned to the wet clutch type.

Control system

It is Mechatronic that controls the processes occurring inside the DSG. System components:

• input sensors recording the position of the gear shift forks, shaft rotation speed, oil pressure and temperature readings, opening degree throttle valve etc.;
• electronic control unit;
• electrohydraulic unit, which is a complex of actuators. It includes valve spools, solenoid valves, oil pressure control valves, and a multiplexer.

Putting the puzzle together

It remains to consider only a few features of the DSG device, allowing us to understand how the preliminary engagement of the next gear is implemented. The main secret is that the gearbox has two input shafts. They are located coaxially (one passes inside the other) and are each connected to its own clutch.

One of the shafts is designed for an even number of speeds, the other for odd steps and reverse gear. In driving mode, the wheels are connected to only one input shaft. The amount of torque, that is, the gear, is determined by which gear of the secondary shaft the input shaft is currently connected to. At the moment when one of the clutches connects the input shaft to one of the secondary shafts, the second secondary shaft rotates freely, which allows the next gear to be selected through synchronizers. When the mechatronics decides that the right moment has come to engage the gear, it will open one clutch and immediately engage the second. Exactly the one whose shaft is already connected to the gear of the next gear.

The type of drive installed in the vehicle determines the wet clutch layout. A more compact option is concentric (friction discs are located in the same plane). For rear-wheel drive cars, a parallel arrangement of couplings is used (located perpendicular to the shaft, the packages stand one after the other). The type of drive axle also determines the layout of the gearbox itself.

Danger of buying

It is worth recognizing that the smoothness of switching and the speed of switching are very expensive for many owners of cars with DSG. Major breakdowns:

• DQ250 - rapid failure of the dual-mass flywheel. The problem here is not with the DSG, but with the unreliable design of the flywheel element. The appearance of vibrations accelerates the failure of the double clutch;
• DQ200 – flywheel problem fixed. But a dry clutch wears out much faster. Reducing the amount of oil leads to frequent overheating. The double clutch handles constant hard acceleration very poorly. Designers, trying to extend the life of the automatic transmission, programmatically underestimate the characteristics of the internal combustion engine, smoothing out reactions to sharp pressing of the accelerator pedal;
• overheating – a common problem all DSGs, but the worst situation in this regard is for automatic transmissions with a dry clutch;
• mechatronics malfunction. A typical failure for the DQ200 and DQ250, but there are precedents for the DQ500;
• failure of the differential pinion axis is a problem that has migrated to the newer manual transmissions. Fortunately for owners, malfunctions are infrequent.

How to be

Jerks or vibrations when switching, kicks, constant sounds and gears that do not engage can catch the owner new car already from 30 thousand km. Problem-free operation of the DQ200 rarely lasts more than 70 thousand km. During normal operation, the DQ250 can run more than 100 thousand km. This situation is truly frightening, because the service life of torque converter-type automatic transmissions is often not limited to 250 thousand km. Some models, with regular oil changes and careful operation, cover up to 400 thousand km. At the moment, the best DSG transmission is the DQ500, installed on all-wheel drive cars. The front-wheel drive layout is more prone to overheating. Much, of course, depends on the conditions in which the car is driven. What harms a robotic gearbox:

• long driving in traffic jams (especially in summer);
• dynamic driving with sharp accelerations;
• incorrect chip tuning.

Now you know what DSG is. In addition to the above information, owners can be advised to change the oil every 30 thousand km in a gearbox with a wet clutch. This will significantly extend the service life. The question of the feasibility of purchasing used cars with DSG deserves special attention.