A close-up shot of a 7-speed DSG gearbox
The 7-speed DSG gearbox, particularly the dry clutch variant, is known to exhibit several common faults. This comprehensive guide will delve into the issues that plague the Audi S Tronic, VW, Seat, and Skoda DSG 7-speed models, and how these can be repaired or even upgraded with modified parts by ASR Gearbox Repairs, the UK’s leading gearbox repair company.
Please note: This guide is specifically tailored for the DSG 7 Dry Clutch systems found on models with an engine capacity of under 2000cc. It does not pertain to the OB5/DL501 DSG 7 gear wet clutch system equipped on the larger Audi models.
An Introduction to the DSG 7-Speed Transmission
The DSG gearbox, often referred to by various names including 0AM, 0CW, 7DSG, and DQ200, is commonly found in smaller engine models in the Audi, Seat, Skoda, and VW range. Despite its widespread use, this model of DSG gearbox is not immune to faults.
Fortunately, all these faults have viable repair solutions, and at ASR Gearbox Repairs, we have the expertise to resolve these issues efficiently and cost-effectively.
Table of Contents
Mechatronic Faults and DSG Fault Codes
The 0AM DQ200 DCT mechatronic unit is prone to various faults, which can lead to harsh or incorrect gear changes, or even complete loss of drive. This semi-automatic dual clutch gearbox relies on the correct function of the mechatronic to regulate clutch operation as well as gear changing. Faulty DSG mechatronic units can result in damage to the gears and reduced service life of the dual clutch pack.
At ASR Gearbox Repairs, we have the expertise to diagnose and repair these faults, ensuring your vehicle is back on the road as quickly as possible. We offer a much more affordable solution than main dealers, without compromising on quality or service.
Common Faults
Internal high-pressure hydraulic leaks
- Very common
- Requires rebuild or complete replacement mechatronic unit.
TCU failure
- Common
- Requires replacement TCU or complete mechatronic unit.
External low-pressure leaks
- Uncommon
- Requires rebuild of mechatronic or complete mechatronic.
DQ200 DSG Fault Codes
DQ200 Fault Codes on Diagnostics
- P17BF – Hydraulic pump system overload protection
- 06079 – Hydraulic pump, play protection
- 06300 – Function restriction, due to insufficient pressure build up
- 06293 – Function restriction due to pressure drop
- Shaking / juddering in 1st gear and when changing into higher gears
- Current gear flashes on dashboard
- Flashing engine management light or PRNDS on dashboard
- Clutch slip or banging on engagement
Note: You may experience some, but not all of the listed faults depending on the level of internal damage.
We always recommend having your mechatronic faults repaired by a company that can complete everything in house. This can save time from mis-diagnosis and damage of the unit in transit which is very common.
Many of the customers vehicles that we see at our workshop have had their mechatronic units sent off prior to coming to us and a result of “no fault found” was given, however their gearbox issues still persisted. When we take a closer look, we find cracks in the valve body resulting in pressure loss issues as well as faulty solenoids.
Mechatronic Part Numbers
0AM 927 769 D – 0AM 927 769 D
0AM 927 769 K – 0AM 927 769 K
0AM 927 769 G – 0AM 927 769 G
0AM 325 025 D – 0AM 325 025 D
0AM 325 025 H – 0AM 325 025 H
0AM 325 065 N – 0AM 325 065 N
0AM 325 025 J – 0AM 325 025 J
0AM 325 065 L – 0AM 325 065 L
0AM 325 065 S – 0AM 325 065 S
Components That Fail in the 7-Speed DSG Mechatronic Unit
This section will provide an overview of the components that make up the DQ200 mechatronic unit and the common failures for each part. At ASR Gearbox Repairs, we have the expertise to diagnose and repair these components, ensuring your vehicle performs at its best.
High-Pressure Leak from Accumulating Canister
The valve body on the DQ200 0AM mechatronic unit has a design flaw where the thickness of the locating canister wall is too thin. This can cause it to split, leading to a loss of high pressure and issues with the clutch and gear operating system. When the damage reaches a severe stage, the vehicle may not drive, or it may exhibit very rough gear changes, jerking motions, and fault warnings on the dashboard.
Fortunately, this issue can be rectified by ASR Gearbox Repairs, by reconditioning the mechatronic unit and upgrading the valvebody with the new superseded design which VW/Audi addressed and which cures this issue.
IC Motor & High-Pressure Pump
The IC motor and high-pressure pump are common components for failing on the DCT DSG mechatronic unit. Pressure leaks can cause the high-pressure pump to overwork and burn out. However, the failure of these two components is usually secondary issues, which are often misdiagnosed as the primary suspects. At ASR Gearbox Repairs, we ensure accurate diagnosis and effective repairs.
Solenoid Valve Fault
Solenoid failure is very common on the VW DSG, Audi S-Tronic 7 Speed Mechatronic units. Failures can be caused by contamination in the oil from component breakdown, as well as internal electrical faults. We can diagnose these issues and perform the necessary repairs to get your vehicle back on the road.
DSG7 Reverse Selector Fault
One particular issue that customers often face is that their vehicle doesn’t go into reverse or they cannot select 6th gear. This fault is a case of “when” not “if” for DSG 7 speed vehicles older than 2018.
A fault with the reverse selector is often mis-diagnosed as a mechatronic issue. The collapsed selector fork triggers error codes relating to pressure and selection faults and often causes less experienced repairers to recommend expensive mechatronic repairs when they are not needed.
When the bearing/slider fails, the selector is left unsupported in its guide bush and allows the fork to move in a lateral direction, opposed to its normally guided vertical motion. When the selector is in this state the mechatronic can not operate the selector properly resulting in no or poor gear selection. At this point, the misaligned selector can damage the gear position sensor on the mechatronic unit and will require the removal of the complete mechatronic for remanufacturing.
This fault is exclusively found on the 0AM 7 Speed DSG DQ200 gearbox models. The replacement of this component in the unit will greatly improve the DSG gearbox reliability.
Common Faults
Reverse selector bearing failure
- Very common
- Requires strip down of transmission and replacement of bearing or upgraded selector fork.
Symptoms
- Fault code 06293 function restriction due to pressure drop
- Fault code 01851 stuck in gear 6
- Grinding/crunching sound when selecting reverse
- Complete loss of reverse gear
- Flashing engine management light or PRNDS on dashboard
- 6th gear does not engage
Note: You may experience some, but not all of the listed faults depending on the level of internal damage.
DSG Clutches: Common Faults
The DSG clutches on the 7-speed gearbox are made of two individual friction material design discs, housed in one unit with two operating diaphragms. As they are constructed in a similar way and of the same material as your standard manual transmission clutch, they also suffer from the same wear and tear issues and failures.
DSG clutch wear in the 7 speed gearbox result in clutch judder when accelerating from standstill or when changing gears. It can also produce an over-revving effect as the DSG clutches slip and struggles to gain grip to transmit the power from the engine through the gearbox. These symptoms are usually accompanied by a fault code on the system relating to the clutch (clutch 1/2 tolerance limit reached).
In more severe cases the engagement of the DSG clutch pack can result in a heavy/violent bang, which can stall the engine. It is highly recommended to change the clutch before this point as it can cause additional damage to the dual mass flywheel.
It is vitally important that the DSG clutches are installed by an experienced mechanic and shimmed correctly using the specialist tools required. We have numerous customers come to us believing they have issues with their mechatronic unit, for us to discover their DSG clutch has been installed incorrectly, which drastically reduces it’s lifespan.
Common Faults
Clutch pack wear
- Very common
- Requires removal of transmission and replacement of DSG clutch with new OEM approved unit.
Symptoms
- Clutch judder when accelerating from standstill or when changing gears
- Over-revving effect as the DSG clutches slip and struggle to gain grip
- Heavy/violent bang on the engagement of the DSG clutch pack, which can stall the engine
Note: It is vitally important that the DSG clutches are installed by an experienced and approved mechanic, then shimmed correctly using the specialist tools required. At ASR Gearbox Repairs, we ensure that all installations are performed to manufacturer standards.
Bearing Failure
While bearing failure is not as common as mechatronic, clutch pack, and reverse selector failure, it does occur and can lead to significant issues.
The differential bearings are almost always the main culprit and result in a very audible constant whining sound when driving.
Bearing wear on individual shafts is also common which will cause an audible whine in certain gears and can also be heard slowing down as the transmission shifts power from one shaft to another.
Common Faults
Bearing wear
- Uncommon
- Requires strip down of transmission and replacement of bearings.
Symptoms
- Audible constant whining sound when driving due to differential bearing wear
- Audible whine in certain gears due to individual shaft bearing wear
Vehicle Models Affected
The following vehicle models are known to be affected by these DSG gearbox issues:
Audi:
- A1 DSG (’11 onwards)
- A3 DSG (’08 onwards)
- A3 Cabriolet DSG (’08 onwards)
Seat:
- Altea DSG (’09 onwards)
- Ibiza DSG (’08 onwards)
- Leon DSG (’09 onwards)
- Toledo DSG (’09 onwards)
Skoda:
- Octavia DSG (’08 onwards)
- Superb DSG (’08 onwards)
- Yeti DSG (’10 onwards)
Volkswagen:
- Golf DSG (’07 onwards)
- Golf Plus DSG (’07 onwards)
- Jetta DSG (’07 onwards)
- Passat DSG (’08 onwards)
- Passat CC DSG (’10 onwards)
- Polo DSG (’09 onwards)
- Scirocco DSG (’08 onwards)
- Touran DSG (’08 onwards)
Our DSG Repair Services
At ASR Gearbox Repairs, we specialize in the comprehensive repair of DSG gearboxes. Our team of seasoned technicians has the expertise to diagnose and rectify a wide array of issues, ensuring swift restoration of your vehicle’s functionality. Unlike main dealers who provide estimates solely for a new gearbox should any sort of issue arise, our approach focuses on identifying and fixing individual problems. This strategy enables us to offer a significantly more cost-effective solution, maintaining the same, if not superior, quality without compromise.
If you suspect your vehicle might be suffering from a fault, it is best to get it looked at straight away as it could save you a substantial amount on your repair bill. ASR offers an initial diagnostic service with our specialist diagnostic equipment. This shows us live data from the gearbox as well as a report for the customer to see the fault codes within the DSG unit. This essential first step is £90 including VAT.
All of our DSG repairs or reconditioned units come with a minimum 12 Month / 12,000 Mile Warranty.
Tel: 0207 096 5044
Email: info@asrgearboxrepairs.co.uk
Disclaimer: Our assessment of how common faults are with certain aspects of this transmission, are based on the work we have carried out over time and the percentage between each type of job. This is not an official statistical value of the VAG transmission range.
Frequently asked questions
DSG gearbox issues are not uncommon, especially in certain models. However, the frequency of these issues can vary based on a variety of factors, including the age and condition of the vehicle, driving habits, and maintenance history.
Yes, at ASR Gearbox Repairs, we have the expertise and resources to diagnose and repair all types of DSG gearbox issues. Our team of experienced mechanics uses the latest tools and techniques to ensure your vehicle is repaired to the highest standards.
The cost of repairing a DSG gearbox can vary depending on the nature and extent of the issue. However, at ASR Gearbox Repairs, we strive to offer a more affordable solution than main dealers. We also offer an initial electronic diagnostic service for £90 including VAT.
The repair time can vary depending on the nature and extent of the issue. However, we understand the importance of getting your vehicle back on the road as quickly as possible and strive to complete all repairs in a timely manner.
Yes, all of our DSG repairs or reconditioned units come with a minimum 12 Month / 12,000 Mile Warranty. This gives you peace of mind knowing that your vehicle is covered in the event of any issues following the repair.
For more information or to book a repair, contact us today.
Frequently asked questions
DSG gearbox issues are not uncommon, especially in certain models. However, the frequency of these issues can vary based on a variety of factors, including the age and condition of the vehicle, driving habits, and maintenance history.
Yes, at ASR Gearbox Repairs, we have the expertise and resources to diagnose and repair all types of DSG gearbox issues. Our team of experienced mechanics uses the latest tools and techniques to ensure your vehicle is repaired to the highest standards.
The cost of repairing a DSG gearbox can vary depending on the nature and extent of the issue. However, at ASR Gearbox Repairs, we strive to offer a more affordable solution than main dealers. We also offer an initial electronic diagnostic service for £90 including VAT.
The repair time can vary depending on the nature and extent of the issue. However, we understand the importance of getting your vehicle back on the road as quickly as possible and strive to complete all repairs in a timely manner.
Yes, all of our DSG repairs or reconditioned units come with a minimum 12 Month / 12,000 Mile Warranty. This gives you peace of mind knowing that your vehicle is covered in the event of any issues following the repair.
For more information or to book a repair, contact us today.
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With an impressive 26-year tenure in the industry. His expertise spans from the inner workings to the most complex technical issues, providing an all-encompassing understanding of gearboxes. A living encyclopedia in his field. He now brings this extensive knowledge to his role as a lead technician at ASR Gearbox Repairs.
