02E Basic Settings Tips

Sometimes the DSG will start chaning badly up or down, you will feel that it is jerky or some other strange things and noises you are not used with and you will think that disaster has hit you. It is not always the case.

Before you jump to any conclusion regarding your "defective" DSG6 02E Gearbox, I recommend you to do the following things.

• Change your Oil and Oil Filter in the transmission.
• Check all your ABS sensors
• Make sure your ENGINE runs fine and you do not have any problems with fueling, spark plugs, fuel filter ... well, you know all the stuff that make an engine run :)
• Check your engine mounts , gearbox mounts and the pendulum mount under the car.
• Check all the other things I mentioned in my previous post 

 If all this is OK then perform a basic settings to on the transmission using VCDS or VAS.

The procedure can be found on Ross Tech website and I will not list it here.

I just want to point out a few things here. Before you start basic settings pay attention on the software version of your unit.

As example here the software NUMBER / VERSION on this unit is 1814:

When you arrive at the step that is saying :  "Clutch Adaptation Control Module Software Version < xxxx"
If  your software version is over 0800 , you don't need to perform Group 62 , just SKIP this step and go to the next Group which is Group 067.

Now when the basic settings are complete in order to achieve best results you will have to drive in Manual mode until CLUTCH 1 and CLUTCH 2 have learned the clamping point AT LEAST 10 TIMES EACH !!!

Ross Teech does not specify this, but in order to achieve this you must drive in Manual mode at CONSTANT SPEED (do not use cruise control) on each CLUTCH for at least 10-15 seconds.
What does this mean.

Lets's say you start driving and you are in 3'rd gear.

1. Keep constant speed with RPM between 2000 and 3000 RPM for at least 10-15 Seconds.
When this is achieved, change up to 4th gear and repeat
2.In 4th gear, drive at constant speed , constant RPM (2000-3000 rpm) for 10-15 Seconds.
3. Change either UP or DOWN and again drive at constant speed / rpm for 10-15 seconds.
4. Repeat step 3.

Learning clamp point must be done in 3-4-5-6 gear and the clutches must change at least 20 times between odd and even gears (10 times per clutch).
This way you will achieve the best results.

DSG Files

DSG 6 - DQ250 Ori Files - Original DSG 6 Files.

I am still thinking if I will or I will not post this DSG 6 Original files on the website.... maybe soon. In the meantime if you need any ORIGINAL or TUNING files for your DQ250 DSG 6 Gearbox / DQ200 DSG 7 please send me an e-mail and we will see what we can do about it.

I am always open to any suggestion regarding exchange of files, even if there are very few files that I do not have, I might still need some older software versions. 

Since I posted this article , I created an online web shop for all your DSG Flash file needs.
You can visit the portal at www.dsgfiles.com !

You can search for files there and if the file is not online , just use the contact form to request it.

DSG Repair

As I said some of the problems with the DQ250 Gearbox and the MEchatronic unit from this gearbox (DSG 02E) can be fixed. Most common problems are :
 

• Flashing PRNDS in the Dash and the gearbox will switch to neutral.
• Hard engaging of the 1st gear (slams into the first gear) from a stand still point.  This can sometimes also be caused by a decallibration of the clutches so you might be able to "save the day"  by performing a recalibration with a VCDS cable. Procedure can be found on Ross Tech website.
• Hard downshifting from 3 to 2 and 2 to 1st gear followed by some loud "clunk" noises.
• Shaking / juddering feeling while in 2nd , 3rd gear and the car pulls up.
• Jerking between gears
• Loss of power between 1300-2000 RPM. Car feels like it has no power.

Some of the affected units are :

02E927770E
02E927770AE
02E927770AJ
02E927770L
02E927770G
02E325025AD
02E325025ADZ01
02E325025ADZ02
02E325025ADZ03
02E325025ADZ04
02E325025ADZ05
02E325025ADZ06
02E325025ADZ07
02E325025ADZ08
02E325025ADZ09
02E325025ADZ0A
02E325025ADZ0B
02E325025ADZ0C
02E325025ADZ0D

There are many other symptoms but here I described just a few of them. BEFORE you send me any DSG problems related questions I would suggest you to try the following :

1. Change your DSG Oil and Oil Filter. When changing look for metal residues in the oil or the oil filter. MAKE sure you fill up the gearbox oil to the specified levels.
2. Perform Basic Settings as described on Ross Tech website.
3. Make sure you don't have any oil leaks from the gearbox and the oil is at the correct level.
4. Check your ABS Sensors. Check if all 4 sensors read same speed while driving. (have another person driving with you and monitoring while driving, make a log file). ABS Sensor can be a pain when talking DSG Gearbox shifting.
5. Change your fuel filter. Especially on diesel cars check the fuel filter and see if you don't have any oil in the filter. The high pressure vacuum pump tends to fail and mix oil into the diesel.
6. Check your DMF (Dual Mass Flywheel). Take the Starter motor down (it's 2 screws) and check if you have any play.

AFTER you have done this and you still feel like you have a problem with the DSG Gearbox or the Mechatronic module and you would like some advice, you can send me an e-mail at jaxelos @ gmail.com with any questions you might have. If and when you do so PLEASE include as many details about your car as possible (Make, model, year, engine size and code, gearbox code). This will save me and you some precious time.

 

DSG Remap , DSG Tuning

I can offer both DSG Tuning and Engine Tuning upon request.

After a while some people tend to get bored with their car and will want to start improving the performance and make some modifications to their cars. Some people will want tuning , other will want styling. Those that want tuning will always try to push their car to the limits in order to achieve better performance, a better driving experience, a bit more adrenaline.

As we know there are quite a few modifications that can be done to an engine in order to achieve better performance, and once you have started tuning your engine on a car with DSG gearbox, sometimes you will also want more from your gearbox. There is not much you can change on a manual gearbox without splitting it apart, but on the DSG field there are new possibilities.

Many modifications can be made to the software inside the DSG Gearbox (actually in the software of the Mechatronic unit) in order to have a better car. Some of the most common DSG Tuning that can be done:

- Custom D and S program
- Increased Torque limiter
- Torque capacity upgrade to 450-500Nm
- Quiker Shifting time
- Max. shifting RPM
- Less unwanted use of 1st gear
- Raised downshift rpm
- Deactivation of automatic up-shift in M
- Modified gear ratio control for longer gears
- Paddle activation
- Modified launch control rpm
- Disable Kick Down in M-Mode

- Indivdual calibration of the shifting maps in D- or S- Mode

And many more individual settings.

In order to achieve the best out of your DSG Remap software I would need to know if your car is remapped and if possible to provide the remap for me. If this is not possible you might experience clutch slipping because of overboost or because the boos is built up to fast for the DSG to clamp.

If you need any DSG tuning file please contact me by mail at jaxelos @ gmail.com and will see what can be done for you.

DSG 02E Advanced ID, DSG6 DQ250 VCDS Advanced ID

Most people send me questions regarding what mechatronic units will fit into their cars and in order to be able to answer to this questions I need to know the ID of the current unit installed in the car.

Here you can see how to get a proper Advanced ID of the DSG6 Mechatronic unit using VCDS from Ross Tech.

This information is necessary to determine the proper software that needs to be flashed on a mechatronic unit in case you want to change mechatronic units.
I will later post same procedure with VAS and VCP.

Flashing / Programming DSG7 DQ200 Mechatronic unit 0AM927769D using VAS

Short video on how to flash the DSG7 0AM927769D DQ200 mechatronic units with wet clutch using VAS 5054. This units can be found on many DSG7 cars and are mostly sold blank so you will need to flash them with the correct software before installing them in the car.
This video is added by request from many users. If you want me to add other videos , let me know what would you like to see and I will do my best to add it.



I ALWAYS recommend VAS head for flashing and VAS , Odis or VCP for slashing SGO files. 

.....
VAS Is no longer such a good idea for flashing as it is very old and only compatible with Windows XP and Windows 7 , so I recommend using ODIS.

Changing DSG Solenoids

Here is how to change the DSG Solenoids on a Mechatronic unit from the DSG 6 02E DQ250

Cleaning DSG 6 Mechatronic unit

Here below is one of my old videos while I dismantled and put back together the DQ250 Mechatronic unit.
Some more videos will come soon. This was a defective unit and I have made the video just for documentation.
It was a long long time time ago :)

 

DSG 02E Gearbox Recommendations

DSG it is pretty strong in terms of mechanics , If you want to keep your DSG gearbox in good condition I would recommend the following :

- Changing oil before the 60.000km indicated in the book (I recommend 40-45.000km as the gearbox is very sensitive about oil quality and you can never drain it all)
- Do not overheat the car and do not push it to its limits when HOT.
- Keep the engine in good working condition (smallest problems can influence how the gearbox changes and reacts).
- Once in a while check the rear wheel bearings on the rear wheels (they have the ABS rings built in) and if you feel they are noisy change them.
- Do not drive with the car in water that can go above your DSG connector on the gearbox.
- Keep the engine room clean and once in a while (every 2-3 years) clean all the earth connections in the engine bay.
- Check your fuel filter for oil residues and change it regularly. (On some engines the vacuum pump tends to leak oil)
- Check the condition of the DMF and if it's noisy or it has play, change it before it damages the clutches, drive shafts.
- Check Cooling fluid level regularly and if it drops below level and you can not see where the water goes, check gearbox oil for contamination. DSG oil coolers tend to break and oil contamination will occur.

- Check your Engine Mounts and Gearbox Mount , worn mounts can cause discomfort when changing gears, cause "clank" noises and so long.

Need Help ? Tech Support

If you need parts or you have any problems with your DSG Gearbox of the Mechatronic unit please drop me an e-mail at jaxelos @ gmail.com and I would be more than happy to help if I can.

I can fix /repair Mechatronic units including the circuit boards if necessary.

BEFORE YOU SEND ME ANY QUESTIONS regarding problems with your DSG gearbox make sure you have checked the following: 

• ALL YOUR ABS Sensors are working in perfect condition. You can log the signal of all 4 sensors with the VCDS Tester. or VCP. The most important one here is the REAR wheel sensors.
• Make sure your diesel filter is changed and not filled up with oil.
• You changed the DSG oil and filter and you performed the DSG Adaptation correctly.
• You have no other errors on the engine control management.
• Your EGR Valve is in good working condition and engine runs as it should.
• CHECK your VACUUM Pump and be sure there are NO OIL LEAKS that will reduce the Vacuum necessary for the perfect working condition of the engine.

In order to get a better overview of your problem please try to DESCRIBE the problem as good as possible but do no write me a whole novella.
Remember to say "HI" and present yourself so I know who I am writing with and please
tell me from where you are!

I will NOT answer e-mails like this :

"I have a problem with my DSG, please help me"
or
"Do you have a file for DSG6 6?"
or similar e-mail. I will try to help the people who really need the help but please do not waste my time.
If you have a LOG file with the errors of the car please SEND the log file along with the e-mail.
Send me some details about the car also : Make, model, year, engine code, gearbox code,VIN number and please try to get the error codes... as many details about the problem as possible.

I RECEIVE INSANE HUGE AMOUNTS OF E-MAIL RELATED TO DSG PROBLEMS LATELY AND I SIMPLY
DO NOT HAVE TIME TO ANSWER EVERYBODY ANYMORE , SORRY !!

WITH MANY PEOPLE I USE DAYS TO TRY AND DIAGNOSE A PROBLEM AND AT THE END I DO NOT EVEN RECEIVE A "THANKS".

IF YOU THINK MY TIME IS WORTH SOMETHING AND YOU REALLY NEED MY HELP PLEASE MAKE A SMALL DONATION TROUGH PAYPAL.

DSG 02E Common Problems DQ250

Some of the most common symptoms of a Mechatronic Failure are :

• Flashing PRNDS in the Dash and the gearbox will switch to neutral.
• Hard engaging of the 1st gear (slams into the first gear) from a stand still point.  This can sometimes also be caused by a decallibration of the clutches so you might be able to "save the day"  by performing a recalibration with a VCDS cable. Procedure can be found on Ross Tech website. *
• Hard downshifting from 3 to 2 and 2 to 1st gear followed by some loud "clunk" noises. *
• Shaking / juddering feeling while in 2nd gear and the car pulls up. *
• Jerking between gears *
  * This problems can be caused by worn valves. Changing the affected valve might solve your problem.
• Loss of power between 1300-2000 RPM. Car feels like dead

If you have any other experiences please let me know, I will add them.

For whoever needs I can supply electronic parts for the DQ250 DSG Mechatronic / Mechatronik units.

18222 P1814 Pressure Control Valve 1 (N215), Open / Short to Ground **
18223 P1815 Pressure Control Solenoid 1 (N215), Short to B+ **
18226 P1818 Pressure Control Solenoid 2 (N216), electrical malfunction **
18227 P1819 Pressure Control Solenoid 2 (N216), Open / Short to Ground **
18228 P1820 Pressure Control Solenoid 2 (N216), Short to B+ **

** This errors can be caused by insufficient oil in the gearbox. Please check the level and the quality of oil first.

18231 P1823 Pressure Control Solenoid 3 (N217), electrical malfunction
18232 P1824 Pressure Control Solenoid 3 (N217), Open / Short to Ground
18233 P1825 Pressure Control Solenoid 3 (N217), Short to B+
18236 P1828 Pressure Control Solenoid 4 (N218), electrical malfunction
18237 P1829 Pressure Control Solenoid 4 (N218), Open / Short to Ground
18238 P1830 Pressure Control Valve 4 (N218), Short to Plus
18241 P1833 Pressure Control Solenoid 5 (N233), electrical malfunction
18242 P1834 Pressure Control Solenoid 5 (N233) Open / Short to Ground
18243 P1835 Pressure Control Solenoid 5 (N233) Short to B+
18246 P1838 Pressure Control Solenoid 6 (N371), electrical malfunction
18247 P1839 Pressure Control Solenoid 6 (N371) Open / Short to Ground
18248 P1840 Pressure Control Solenoid 6 (N371) Short to B+

  The following error is most likely caused by a mechanical problem but can also be an error on the Mechatronic unit:

19143 - Unexpected / Implausible Mechanical Gear Disengagement
P2711 - 004 - - Intermittent

 

VAG DSG Problems..

Currently, the world of transmission is dominated in Europe by manual gearboxes and in the USA and
Japan by automatic gearboxes. Both types of gearboxes have specific advantages and disadvantages.
The advantages of a manual gearbox are, for example,
• high degree of efficiency
• robust and sporty characteristic.
The advantages of an automatic gearbox are, for example,
• a high level of comfort, above all in gear changes, as there is no interruption in tractive power.
This formed the framework for Volkswagen to combine both transmission concepts into one completely
new gearbox generation: the direct shift gearbox.

Thanks to the double multi-plate clutch design and different automatic gear selection programmes, it is
well capable of meeting the high demands in comfort from drivers who favour automatic gearboxes.
Furthermore, with direct selection and lightning fast, jolt-free gear changes, it also offers a high level of
driving enjoyment to drivers who favour manual gearboxes.
In both cases, fuel consumption is at a par with economical vehicles fitted with manual gearboxes.

Well, like all gearboxes, the DSG Gearbox has it's problems also.
Although it is a strong gearbox some components are still pron to fail , in this case the mechatronic units , the heart of the gearbox, it is was not built as strong as VW thought it was.
It seems that most affected cars are the VW Passat , VW Touran and the VW Golf produced between 2003 and 2007. I have only seen a few Skoda and a few Seat.

But there is a problem with this DSG Gearboxes, it's the Mechatronic unit. This unit sits inside the gearbox and it gets pretty hot and sometimes the electric valves will get defective. Also a common problem with the DQ250 Mechatronic unit is a faulty TCM electronic module. This is mostly seen when the gearbox oil temperature goes above 40 degrees Celsius and we will start seeing error codes as "18222 P1814 Pressure Control Valve 1 (N215), Open / Short to Ground" or some other Short to Ground errors on the other valves.

Most of the valves can be refurbished but until now I have never seen anyone being able to refurbish the Pressure Control N215 or Pressure Control N216.

DSG Manuals

Before you start take a few moments to study this manuals I have here for you :

• Self-study programme is designed to help you understand the Direct Shift Gearbox
• The DSG Dual-Clutch Gearbox Environmental Commendation – Background Report
• 6-Speed Automatic Transmission 09G/09M Design and Function
• DSG 02E Repair Manual
• Double clutch gearbox 02E (DSG) Electric Connections VW Golf
• Dual clutch gearbox 02E Electrical Connections - Passat

Read them , they might be useful to you some day :) I know they have been for me.

About DSG Gearboxes

"A direct-shift gearbox (German: Direkt-Schalt-Getriebe[1]), commonly abbreviated to DSG, is an electronically controlled dual-clutch multiple-shaft manual gearbox, in a transaxle design – without a conventional clutch pedal, and with full automatic,or semi-manual control. The first actual dual-clutch transmissions derived from Porsche in-house development for 962 racing cars in the 1980s.

In simple terms, a DSG is two separate manual gearboxes (and clutches), contained within one housing, and working as one unit. It was designed by BorgWarner, and was initially licensed to the Volkswagen Group, with support by IAV GmbH.By using two independent clutches,a DSG can achieve faster shift times,and eliminates the torque converter of a conventional epicyclic automatic transmission." - From Wikipedia

    I have decided to dedicated the whole site to the VAG DSG Gearboxes and Mechatronic units. Information will be added graduate or upon request. You will also be able to find here DSG DQ250 Gearbox manuals, DSG Repair Manuals, DSG Pressure Control Valves information and many other things related to the DSG Mechatronic units and gearboxes.

    If you need DSG Mechatronic Solenoid / Valve take a look in the VAG DSG Gearbox section.
    Standard and custom software for the 02E DQ250 DSG 6 gearbox and DQ200 DSG 7 gearboxes also available upon request.

VAG DSG 6 Gearbox and how all started.

I have decided to move my tech page into a blog.
Many people ask questions, post comments and in this way will be faster to answer.
Also I can see not to many people are donating for the support I give so I will have to place some adds on the page.

I have started my journey with the VAG DSG Gearboxes about 10 years ago when I first encountered problems with my own VW Passat DSG and there it all started.
I just refused to pay VW a huge amount of money to repair my DSG Gearbox and I opted for the hard way and started to learn as much as I can.

First I bought a DSG Mechatronic unit for my DSG6 DQ250 , and I thought .. heh , this is going to be an easy job.
Uninstalled my own Mechatronic from the car and installed the newly purchased one into the DSG Gearbox. After quite a few hours of hard work I filled up oil, started the car and went for a test drive.
To my disappointment this was a short trip as my car did not want to change gears from the second gear up.
I started reading and reading , looking for repair manuals and tech stuff... asked people around, cried for help at all the doors, paid huge amounts of money for hardware and software ........long story short :) .....  after 1 year, two other mechatronic units and an extra gearbox I managed to fix my car. After that I wanted to know more and more and more.... and this is how the whole thing started.
During the 7 years period when I had my first DSG Gearbox car I changed 5 mechatronic units and 3 gearboxes, and this only because I wnated to learn and know everything related to this DSG 6 Gearboxes.

Today I get hundreds of mails from all over the world from people asking for help and I do help as much as I can when I see the people are really trying to solve the problem they have and not just trying to waste my time.

Do if you want my help, PLEASE be detailed when you ask questions, give me as much information as possible, send me log files, tell me details about car , VIN numbers (by mail only) so I can help you... but please don't waste my time.