DSG gearbox: what is it? What's wrong with the DSG box? How dsg works
Robotic boxes burst into the auto world as fast as automatic ones once did. For the first time in mass production and introduction for customers, these boxes were launched by the Volkswagen concern. This article will tell you about what a DSG box is, how it works, how it differs from an automatic transmission, the pros and cons, and what car manufacturers say about it.
What is DSG Box?
DSG is a second generation robot gearbox that shifts gears using two clutches and electronically, with the assistance of the driver. Today it is considered the best gearbox and the most reliable. It changes gears without breaking the power and has the best dynamic qualities. DSG also saves fuel, since the internal combustion engine does not idle.
DSG comes in six or seven steps. The first is installed on more powerful cars, since it has more torque. The seven-stage robot is installed on less powerful cars, as well as on some trucks and buses.
Short story
The DSG was first developed by Borg Warner. They wanted to create an ideal gearbox that would combine all the qualities of a manual transmission, an automatic transmission and a variator, and at the same time had no drawbacks. The shortcomings of the mechanics are known to everyone, the machine has power consumption, and the variator has a narrow range of work. The robot had to absorb all these shortcomings, and plus reduce the cost of maintenance and repair.
But things didn't go as they wanted. It turned out that the six-speed gearbox is not suitable for low power cars. Then a seven-speed gearbox was additionally developed, which was suitable for such cars. But the excuses were not confirmed, because it was dry.
A year of work, testing, refinement and a new DSG has been implemented on some Volkswagen vehicles. Of course, there were some incidents, and the first batch was defective. But the plant quickly corrected everything and now the robot is widely used in many cars.
Principle of operation
The genius of the DSG box is that it combines two boxes in one box. It is equipped with two shafts, one with even gears and the other with odd gears. Two clutches, for each shaft, allow the most efficient gear shifting without loss of power and short braking, as in an automatic machine.
The six-speed DSG clutch is of the "wet" type (constantly in oil). This is done so that the discs are cooled and lubrication is constantly present. This function has significantly increased the resource of the checkpoint and it is about 300 thousand km. With careful use, it can stretch up to 450,000 km.
DSG-7, or seven-speed robot box, is equipped with a dry clutch. This is done to reduce the cost of maintenance and service, but at the same time increased wear and decreased resource.
What is the difference between a robot and an automatic transmission?
When buying a car, any car enthusiast thinks about which box is better to take? Repeatedly this confuses a person. So what is the difference between a robot and an automaton?
The first difference is constructive. The robot is made so that the car does not lose power, and gear changes do not slow down the dynamics. The second is a technical difference: this is that the robot is mechanics in its structure and requires
driver's participation in gear shifting.
Other differences between the machine and the robot:
- a robot is simpler than an automatic machine, since by its nature a robotic box is a mechanic;
- the robot has electronics that controls the switching;
- saving fuel by the robot;
- the ability to change the settings of the robot for a different type and manner of driving;
- manufacturability of the design for modern times;
- high reliability and quality of the robot.
Pros and cons of DSG
The advantages are:
- fuel economy (only in comparison with the automatic machine, there is more savings on the variator);
- instant gear change;
- no power loss;
- high resource;
- manual control.
Cons of DSG:
- high cost of repairs;
- expensive cost of oil change (for DSG-6);
- does not tolerate aggressive driving style;
- the cost of the car is more expensive.
Manufacturers' suggestions in robotic boxes
Volkswagen manufacturer promises revision robotic boxes as they are not yet complete. The main problem that automakers set themselves is the reduction in the cost of maintenance and repair. Leaving
advantages, it is necessary to make repairs and maintenance cheaper, since not every ordinary consumer can afford to service a car with such a cost of spare parts and materials.
According to many experts, these boxes are the future, although 40 years ago they were considered not promising and practically dead options. Now they are recruiting supporters and those who would like to have a car with a box.
DSG, but can't afford it. But the manufacturers promise to do everything to make the most available to the average consumer.
Output
Having examined the DSG robotic gearbox, one can come to the conclusion that today it is the most ideal gearbox that combines all the advantages of mechanics and an automatic machine, while not expensive to maintain 😉, like a variator. It has enough of the virtues that modern drivers need.
The automotive industry is developing at an accelerated pace. More and more new technologies appear every year. Some 20 years ago, the automatic transmission was a wonder for many Russian motorists. Today, the list of available transmissions has expanded. If we talk about German cars, then they can often be found with DSG 7. Reviews about it, the device and features of this transmission - further in our article.
Characteristic
So what is this box? It is a robotic transmission manufactured by the Volkswagen-Audi concern. Initially, this box was supposed to have six speeds. However, three years later, a 7-speed DSG box was born. The owners' comments about it were also contradictory. Many people complained about frequent problems (we will look at them a little later). The main goal of the creation is to get a box that would provide gear shifting without interrupting the power flow. This is a key feature of the DSG that sets it apart from other robotic gearboxes. At the same time, a car with DSG has better acceleration dynamics and lower fuel consumption.
To ensure a continuous transmission of torque from the internal combustion engine to the wheels, German engineers used two clutches and two rows of gears. If speak about technical characteristics, DSG 7 is designed for a torque of up to 250 Nm. The working pressure of the accumulator is from 50 to 75 bar. The volume of the filled oil is 1.7 liters.
Device
The box design includes:
- Main gear.
- Dual-mass flywheel.
- Double clutch.
- Two rows of gears.
- Differential.
- Control system.
Principle of operation
The clutch disc, which drives the engine, is located between two driven discs that are connected to the gearbox. One of them is connected to the gears and the shaft of an odd number of gears (first, third, fifth, seventh), and the second is connected to the shaft of even ones (respectively, the second, fourth and sixth). When the machine starts moving, only the odd disc is pressed against the drive disc. This is how the car starts in first gear. With an increase in speed, the odd row is disconnected from the leading disk and the even row is instantly connected. When the latter is running, third gear will already be selected on odd. Due to this, switching occurs instantly. That is, the principle of operation is to sequentially engage the gears of both rows.
Where is it applied?
Since the seven-speed transmission can withstand a small amount of torque, it is used on B and C-class cars, as well as on some cars from the D-segment. More specifically, this transmission is used on cars:
- Volkswagen.
- Seat.
- Skoda.
These are mainly cars with a small engine capacity - up to 1.8 liters. More efficient engines are equipped with a "wet" six-speed DSG.
DSG 7 malfunctions and reviews
Now let's look at the problems associated with this. One of the most common malfunctions concerns the gear shift fork. This element is moved by means of a linear bushing-bearing. It does not withstand the loads imposed on it, since the switching occurs quickly and rigidly. If the bushing is damaged, its inner plate begins to float in the box. This will damage the gears. Due to metal debris, the Hall sensor is clogged, thanks to which the "mechatronic" control system operates. Due to destruction, balls can also fall out. Sometimes the box grinds them too. It can no longer be restored.
There are two forks in the DSG 7 design. Many people believe that only the first and second gear forks can break. But the sixth and rear fork fails at least often. The design of the bearings is identical here. After 2013, German engineers revised the structure of these elements. On new boxes, the bushings have become one-piece, without a ball bearing. What do the reviews say about the Volkswagen DSG 7? With the new sleeve, the box has become really more reliable. But buying used cars before 2013 is still dangerous.
Otherwise, mechanical faults are associated with oil contamination due to broken rods. It is necessary to monitor the purity of the liquid. otherwise, metal dust in the oil can cause:
- Chipping of gears of gears.
- Differential breakage (under increased load, the satellites are welded to the axle).
- Overheating of bearings and complete destruction of the seventh gear.
Other problems happen due to insufficient level oil or due to improper assembly (or transmission settings) after its repair.
Clutch
Almost every owner has faced this problem. As noted by the reviews of the owners, the 7-speed DSG gearbox has flywheel wear. It wears out due to torsional vibrations during slipping and abrupt starts. Also, reviews about the DSG 7 box say that the transmission does not like overheating. The clutch block must be clean.
The slightest dirt is negatively reflected on the quality of DSG 7 work on the Volkswagen Passat. Reviews note that the cost of replacing the clutch assembly is very high. The cost of this operation is from 50 to 80 thousand rubles, which is comparable to the overhaul of any machine. And this despite the fact that the clutch has a small resource. As noted by the reviews, the Skoda DSG 7 should be serviced every 50 thousand kilometers. In 2012, engineers installed a shield on the bore for the release rods. This allowed to reduce the contamination of the crankcase and the wear of the clutch discs. Also note that the transmission needs to adjust the working clearance of the discs. According to reviews, "Skoda-Octavia" with DSG 7 should be configured and serviced only in a specialized service. You should not do any work yourself.
Very often, the resource is reduced due to the movement of the car in traffic jams and over rough terrain. But as the reviews say, the Skoda DSG 7 box does not need to be switched to neutral. Both discs rotate freely from each other. Therefore, by shifting the selector to neutral, you do not in any way reduce the load on the clutch unit and on the mechatronics.
About the resource
As noted by the reviews of the owners, DSG 7 has a short service life. The resource is about 150 thousand kilometers. Further, with the box, more big problems... By the way, even on the new DSG 7, the owners' reviews noticed problems. The box jerks and chooses the wrong revs to change gears.
Breakdowns of mechatronics
We continue to study the reviews about DSG 7. This transmission also has faults related to the electro-hydraulic control unit. Moreover, these breakdowns can affect the mechanical part. As noted by the reviews, DSG 7 has the following faults. It:
- Damage to the electronic board or its sensors.
- Failure of the pressure accumulator.
- Breakdown of the pump motor and control solenoids.
- Problems with the mechatronics housing or accumulator cup. Owners are faced with the phenomenon of channel cracks.
- Loss of tightness of the box and various leaks.
Many had to completely replace the mechatronics of the robotic transmission due to the complexity of the design and the lack of spare parts. The situation got more complicated in 2015. So, the mechatronics began to be stitched and, when installed on another machine, it simply did not work. In view of this, it was impossible to purchase any block from disassembly. I had to fork out for a new one.
Electrical faults
Among the most insignificant reviews are blown fuses in the power circuit. Also on DSG the conductors of the board burn out, damaging its case. Due to breakdowns with the pump, the car simply refuses to go further. Another problem is a burnt out pump winding. The board is ceramic and is very afraid of temperature changes, vibrations and overheating. However, this unit can still be repaired. But this requires the availability of special equipment.
How to save a resource?
- Do not slip at the start.
- In the event of a long stop, turn on neutral mode.
- It is not recommended to move quickly through the rows at speeds up to 50 kilometers per hour.
- Change in time transmission oil(every 40 thousand kilometers).
Summing up
So, we found out what a robotic seven-speed DSG gearbox is. Among its positive aspects, it is worth noting:
- The speed of gear shifting. The gears are switched on almost instantly and even faster than with manual transmissions.
- High accelerating dynamics. This is achieved by continuously supplying torque to the wheels of the car.
- Uniform acceleration. In the case of conventional mechanics or an automatic machine, characteristic jerks are observed during dynamic acceleration and an attempt to change gear.
- Ability to work in manual mode. This function allows the driver to choose the driving style on their own.
But there are also a number of disadvantages due to which many motorists refuse to purchase a car at DSG, in favor of a conventional machine or mechanics:
- Small resource. Even with proper maintenance, such a box travels an average of 150 thousand kilometers.
- Insecurity. We have listed the common breakdowns that occur with a robotic seven-speed DSG gearbox earlier.
- Low liquidity in the market. Many people know about DSG malfunctions, and therefore it will be difficult to sell such a car.
- The complexity of the repair. It is not possible to carry out any repairs yourself. This job requires specialized equipment, knowledge and tools.
- Complex and expensive, a special oil is used, which is more expensive than a conventional "transmission". Also, the replacement can only be performed in the service. And this is an additional cash expenditure.
- The high cost of the car. Cars with DSG are an order of magnitude more expensive than those with a conventional machine.
Should you buy a car with a seven-speed robotic gearbox? There is no definite answer to this question. Experts note that it is advisable to take such a car if it is new and under warranty. Then you can really appreciate the benefits of using DSG without any investment. But if you are settling on a used German car, you should refuse to buy a car with DSG. In most cases, the warranty for this box has expired and the future owner will have to deal with malfunctions on their own. And since the box is very complex, you need to look for specialized services. This significantly affects the cost of car maintenance. The cost of repairing the box turns out to be unreasonably high. Therefore, in the secondary market, preference should be given to mechanics or a classic six-speed automatic.
Now cars are supplied different types boxes. The times when only "mechanics" were installed on cars are long gone. Now more than half of modern cars are equipped with other types of gearboxes. Even domestic manufacturers began to gradually switch to automatic transmissions. Concern "Audi-Volkswagen" almost 10 years ago presented a new transmission - DSG. What is this box? What is her structure? Are there any operational problems? About all this and not only - further in our article.
DSG characteristic
What is this box? DSG is a direct shift transmission.
It is equipped with an automatic gearshift drive. One of the features of the mechatronic DSG is the presence of two clutches.
Design
This transmission is connected to the engine through two coaxially positioned clutch discs. One is responsible for even gears, and the second is for odd and reverse gears. Thanks to this device, the car drives more steadily. The box carries out smooth switching of steps. How does the DSG vending machine work? Let's take an example. The car goes in first gear. When its gears rotate and transmit torque, the second speed is already engaged. It spins idly. When the car shifts to the next stage, the electronic control unit is triggered. At this time, the hydraulic drive of the transmission releases the first and finally closes the second. Torque transfers smoothly from one gear to another. And so on until the sixth or seventh gear. When the car picks up a high enough speed, the transmission will switch to the last stage.
In this case, the gears of the penultimate, that is, the sixth or fifth gear, will be in "idle" engagement. When the speed decreases, the clutch discs of the robotic box will disengage the last stage and come into contact with the penultimate gear. Thus, the engine is in constant contact with the box. At the same time, the "mechanics" by depressing the pedal retracts the clutch disc, and the transmission is no longer in contact with the engine. Here, in the presence of two discs, the transmission of torque is carried out smoothly and without breaking the power.
Advantages
Unlike a conventional automatic transmission, a robotic DSG automatic transmission requires less load, thereby reducing fuel consumption. Also, unlike a simple automatic transmission, the time between everything is reduced due to the presence of two clutches. In addition, the driver can independently switch to the tiptronic mode and mechanically control the gear change. The clutch pedal will function electronically. Now, the ECT system is installed on Skoda, Audi and Volkswagen cars, which not only controls gear changes, but also controls the opening of the throttle valve. Thus, when driving, it feels like you are driving in the same gear. Also, the electronics reads a lot of other data, including the engine temperature. The manufacturer claims that the use of the ECT system can increase the service life of the robotic gearbox and engine by 20 percent.
Another plus is the ability to select the transmission operating mode. There are three of them: winter, economical and sports. As for the latter, the electronics change the moment of the gear change to a later one. So it increases But the fuel consumption also becomes higher.
Transmission problems and malfunctions
Since the robotic DSG gearbox is a complex electromechanical device, it is susceptible to various breakdowns. Let's take a look at them. So the very first problem is grip. It is worth noting here the wear of the basket and the driven disc, as well as the increased load on release bearing... A symptom of a malfunction of these mechanisms is clutch slip. As a result, torque is lost and the acceleration dynamics of the vehicle deteriorates.
Emergency mode occurs What does this mean? A light appears on the dashboard, the car starts to twitch and start badly from a place.
Actuators
DSG problems also apply to actuators. It is an electromechanical gearshift and clutch actuator. With frequent use and high mileage, the so-called "brushes" wear out. Open circuit is not excluded electric motor... A symptom of a malfunction of the acutators is an abrupt start and "jerking" of the car. Also, this symptom occurs when the clutch settings are incorrect. Therefore, it is necessary to carry out computer diagnostics. Each car brand has its own fault codes.
About 7-speed DSG
We already know what this box is. There are no fundamental differences in the operation of six- and seven-stage "robots".
But statistics say that it is these boxes that are most susceptible to breakdowns. If we consider the seven-speed "robot" separately, it is worth noting the problem of the "mechatronic" control unit and the dry-type clutch. The latter is subject to severe wear, especially when switching to an increased or As a result, it wears out and the box goes into "emergency mode". There are slippages, problems when starting from a standstill and shifting gears. The manufacturer Volkswagen itself gives a warranty period of 5 years. During this time, more than half of cars with such a box require clutch replacement. This is the whole problem with this transmission. Therefore, if the car is more than five years old, all responsibility falls entirely on the shoulders of the car owner. And he will change all the nodes in this box for his own money.
Mechatronic
Problems exist not only with the mechanical, but also with the electrical part, namely the control unit. This element is installed in the transmission itself. Since it is constantly subjected to stress, the temperature inside the unit rises.
Because of this, the contacts of the unit burn out, the serviceability of valves and sensors is disrupted. The valve body channels are also clogged. The sensors themselves literally magnetize the wear products of the box - small metal shavings. As a result, the operation of the electro-hydraulic control unit is disrupted. The car starts to slip, does not drive well, up to full stop and the termination of the operation of the units. Also noteworthy is the problem of clutch fork wear. As a result, the box cannot engage one of the gears. There is a hum when driving. This is due to wear. This gearbox is installed on vehicles of different segments. But even on expensive machines, these malfunctions are not excluded, although its nodes are designed for a greater resource and load.
How to extend the service life?
Due to frequent calls to dealerships, the concern itself began to advise car owners on how to extend the life of the box.
In order for the transmission elements to be subjected to less stress, when stopping for more than five seconds, the manufacturer recommends moving the gearbox selector to neutral.
Conclusion
So, we figured out what it is. As you can see, despite its many advantages, it has many problems. Therefore, it is reasonable to drive such cars only if it is on warranty period... Car enthusiasts do not advise buying such cars on the secondary market if they are more than 5 years old. The reliability of these boxes is a big question.
Motorists have many legends about robotic boxes DSG on cars of the Volkswagen concern. Sharp dips in traction and the prohibitive cost of repairs are what everyone is afraid of.
Direct Shift Gearbox (DSG) stands for literally from German as: direct connection box... This is one of the many types of robotic boxes, as you know, the robot is a mechanical box, but with automated control.
When it is necessary to change gears, the computer gives a command that disconnects the clutch disc from the master, thereby disconnecting the engine and the gearbox, moves the gear shafts, then connects the discs back, renewing the torque transmission process. I must say that the computer does not always cope with this operation quickly; it often needs even more time than the driver.
A double-clutch box is a completely different matter. The concept of such a gearbox was invented by the French engineer Adolphe Kegresse. In the late thirties of the last century, he described how the double clutch works.
Technologies of that time did not allow making a prototype, the design was forgotten until the early eighties, then the progressive box was tried on the Ford Fiesta, Ford Ranger and Peugeot 205, and then on Audi and Porsche.
This type of gearbox is called a preselective gearbox (PPC), in addition to DSG, there are several other types of preselective robots, for example, Porsche has pdk boxes developed in conjunction with ZF.
Renault Peugeot Citroen BMW Mercedes and Ferrari use Getrag gearboxes and there are many other dual-clutch gearboxes for special purposes.
There are many selective boxes, but only the Volkswagen DSG are notorious. Largely due to the fact that it was they who first began to be used in the mass production of cars, but there are also subtleties, the DSG design is of 3 types in 2003 came out, a 6-speed version of the DSG box with the dq250 index.
It differs in that the double-clutch discs worked in an oil bath, the friction force between the discs was relatively small, on the one hand, the clutch could transmit a large torque to the gearbox with quite moderate wear, on the other hand, the oil mediator between the rubbing surfaces provided large losses.
In 2008 Volkswagen took a chance and released the dq200 box, so that there were no losses, the clutch from wet became dry, as on ordinary manual transmissions. It was this option that gained unfortunate fame. The box worked very efficiently, but there were problems with comfort and reliability, which we will discuss in detail below.
In 2008, the S-tronik appeared for Audi with a longitudinal engine arrangement. Only DSG 7 should be feared, all other options for selective robots work without unnecessary complaints. Now the Volkswagen concern uses all three versions of the DSG in parallel, as well as the S-tronik.
A car that is equipped with a 7-speed DSG with dual dry clutch can cause problems in operation.
The problem box was placed on almost the entire the lineup Volkswagen of 2008 to this day continue to put dsg7 on relatively weak modifications with engines up to 1.8 liters, with a two-liter or larger engine, as well as diesel engines where the torque is above 250 Hm, this is usually an old and reliable dsg-6 with a wet clutch.
The share of those who are not happy with the purchase is still quite large, owners are worried about jerks when shifting gears up or down. This is the most common drawback caused by the dry clutch discs closing too sharply, the effect is about the same as if on a car with mechanical box drop the clutch pedal.
Also, the car stops responding to pressing the gas pedal, the problem lies in the dry clutch. The mechatronic module that controls the clutch and gearbox is the main cause of DSG breakdowns. True, there are other breakdowns, for example, premature wear of the shaft bearings or the clutch release fork, as well as the adhesion of dirt on the contact sensor. It is rare, as well as on any other gearbox.
Should you buy a car with a 7-speed DSG?
If you choose a used car, then definitely not for 1 year of production, the peak of a problem with a box has come and the buyer of such a car automatically falls into a risk group, the cost of repairs may not be comparable high. As for the new cars, it is possible to choose the 2013 version, the DSG box has undergone modernization, there are fewer problems.
Automotive developers are increasingly improving vehicles equipping them with modern equipment. In particular, this also applies automatic boxes gear. Like any other unit, a gearbox can have its own advantages and disadvantages. We invite you to find out which ones it has - a video about its shortcomings is also at the end of this material.
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