Repair DSG Mechatronic Unit - Guide on How to repair Mechatronic unit Part 1 and 2

I decided to share with the rest of you how to repair the mechatronic units on the DSG6.
To be able to repair your own Mechatronic unit for the DSG6 DQ250 , you will need a few tools.

• A small flat screwdriver
• Screwdriver with T20 bit
• Gloves
• A Dremmel or any small cutting tool with a rotary blade.
• Some masking tape
• Silicone (the one used in cars for the windshield)
• Soldering tools and skills.
• Voltmeter

For the part one I will demonstrate on how to test the DSG Mechatronic unit and its solenoids and how to actually open up the unit and check for damage on the PCB inside the TCM.

First thing you will need is PATIENCE and some steady hands :) Also if you do not have any soldering skills or did not tried to solder before , then this is not the DIY for you, and you can stop here.

Find a CLEAN spot on your garage bench or inside your house and prepare to test the DSG Solenoids with a voltmeter as show in the video bellow. If everything is ok on the outside then you can proced to the next steps and CUT the cover of your unit in order to reach the PCB and the wiring inside.

Please watch the video and leave any questions if you have, I will try to answer the best I can.

  

I have decided to release also Part 2 of DSG DQ250 Mechatronic Repair guide :

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.