Showing posts with label DSG. Show all posts
Showing posts with label DSG. Show all posts

Thursday, March 2, 2017

RECALL

FLASH OF DEATH

The Volkswagen emissions scandal has hardly died down, when we heard that Volkswagen is in the dog box once again. The German car giant is in the process of 
'recalling  as many as 3 million 
Volkswagen's, Audi's, Seats 
and Skoda's  worldwide'
due to DSG (direct-shift gearbox) "gearbox problems" that causes loss of power. This is probably one of the biggest recalls in VW's history. Though in comparison  to Toyota's recall of 10 million cars between 2009 and 2010, amid accident fears over sticky accelerator pedals and floor mats, Volkswagen’s recall is but minuscule.  Some believe that the Volkswagen  recall is  bogus. But it's really good to see that Volkswagen is "stepping up to the plate"


VOLKSWAGEN RECALL

The recall reports that the dreaded 7-dry DSG malfunctions are the result of faulty "temperature sensors" (NTC - thermister) caused by the use of synthetic oil in 7-speed dual-clutch gearboxes.  As such synthetic oil will be replaced with traditional mineral oil. Somehow the Audi 2L TFSI models, the Golf GTI's with the 6-wet DSG and the reliable Tiptronic A/T  are not affected. But that doesn't mean that the wet DSG's are not totally immune to mechatronic failure in the future.  Jetta SportsWagen, GTI and Eos vehicles built between September 2008 and August 2009 and a limited number of 2010 Jetta seem to be most affected. It was probably a bad batch of DSG's.

One is the "false neutral syndrome" where the flashing PRNDS occurs with the car losing all motive power without warning, (traced to a faulty DSG heat/temperature sensor) and the other is where the DSG (direct-shift gearbox; German:- Direkt-Schalt-Getriebe) suffers severe delays at shift points, causing erratic shifting, jerking, long stall pauses, clutch slipping, surging in forward and reverse, etc. 

The "gearbox problem" previously mentioned is non other than the "Flash of Death" aka "DSG Flash of Death" aka "false neutral syndrome", resulting in  a flashing PRNDS. When this happens,  the car loses all motive power without warning, as its transmission goes into limp mode by selecting  3rd gear. But this isn't always the case because subject to the actual "gearbox problem", because the transmission may not disengage. So when the engine is switched off, it may not start thereafter. A second transmission problem revolves around causing erratic shifting, jerking, severe delays at shift points, clutch slipping, surging in both forward and reverse. This  often happens when accelerating, overtaking  or cruising and your VW or Audi is also prone to slip gears and judder at low speeds, even though clutch adaptation may have been done. These faults have been associated with the Mechatronic Unit, bent clutch forks and warped clutch packs. If you have vag-com, you will see that your car threw one or more of the following DTC's, or a variation of them.

17090 - Transmission Range Sensor (F125): Implausible Signal
P0706 - 000 - -

17106 - Transmission Output Speed Sensor (G195): No Signal
P0722 - 000 - - - Intermittent

17114 - Gear Ratio Monitoring: Incorrect Gear Ratio 
P0730 - 35-10 - - - Intermittent

17114 - Incorrect Gear Ratio
P0730 - 000 - - - Intermittent

18113 - Gear Ratio Monitoring: Adaptation Limit Reached
P1705 - 09-10 - Adaptation Limit Surpassed - Intermittent

18149 - Clutch Pressure Adaptation: Limit Reached 
P1741 - 001 - Upper Limit Exceeded - Intermittent

18149 - Clutch Pressure Adaptation: Limit Reached 
P1741 - 35-10 - - - Intermittent

18149 - Clutch Pressure Adaptation: Limit Reached
P1741 - 002 - Lower Limit Exceeded - Intermittent

18151 - Clutch Slip Monitoring: Signal too Large 
P1743 - 35-00 - -

18172 - Transmission Temperature Monitoring
P1764 - 000 - - - Intermittent

18201 - Transmission Output Speed Sensor 2 (G196): No Signal
P1793 - 000 - -

18226 - Pressure Control Valve 2 (N216): Electrical Malfunction
P1818 - 007 - Short to Ground - Intermittent

18226 - Pressure Control Valve 2 (N216): Electrical Malfunction
P1818 - 006 - Short to Plus - Intermittent

28775 - No communication with Gear Selector Module 
U0103-000--MIL ON

28775 - No Communication with Gear Selector Module
U0103 - 004 - No Signal/Communication

MECHATRONIC UNIT

Long story short, your VW or Audi is more likely than not going to need a mechatronic replacement when you experience the above. However, that doesn't mean every transmission problem can be solved by replacing the mechartonic unit.  I know of someone who experienced the "VW DSG Flash of Death". So, he took his Audi to the VW service agents who diagnosed a faulty Mechtronic unit and a faulty wiring harness. Charged him $3500 for parts and labour and three weeks later, "DSG Flash of Death" struck again. The peculiar thing about the "DSG Flash of Death" is that it affects  brand new vehicles. Cars with as little as 3K kilometers on the clock and virtually none of them exceeding 50K on the clock before the DSG (Dreaded Spiteful Genie / direct-shift gearbox) takes revenge. But a faulty mechatronic unit isn't the only problem Volkswagen is facing. Some 30,000 Volkswagen Tiguans are being recalled in the UK alone because of an intermittent fuse / blown fuse problem that causes headlights to cut out. 

The amount of transmission complaints that NHTSA received prompted their lawyers to get Volkswagen to initiate the recall. 
Be that as it may, VW and Audi branded cars sport really great technology, engineering and performance as well as beautiful aesthetics, but what good is all that if the darned car leaves you stranded every so often, costs a bundle to repair and maintain, besides the darn thing can kills you, when limp mode kicks in on the freeway, with fast flowing traffic on your tail.


OTHER VEHICLE RECALLS

Recalls are common in the motor industry but getting the incumbent to take responsible can be a painful as pulling teeth. Recalls are also as common as sand and by the looks of things,  no auto manufacturer is except.  For example, Ford Kuga SUV fire recall goes all the way back to 2013 in South Africa. Now, they are  in the process recalling thousands of its Kuga (fireball) models following client reports that the SUVs self-combusts.  

Honda is recalling an  additional 775 000 vehicles for defective front passenger airbag inflators that was manufactured by the Japanese supplier Takata.

Toyota is globally recalling all the Mirai fuel-cell vehicles  due to a software bug that can shut off its hydrogen-powered system without warning. Toyota is  also recalling more than 300 000 hybrid Prius vehicles globally due to a defect in their parking brakes. 

Volkswagen will recall an additional 50 000 vehicles in China due to brake problems when the cruise control is activated

BMW is recalling some 150 000 cars and SUVs in the US and Canada due to wiring problem to the fuel pumps inside the gas that can cause its engines to suddenly stall.

Mazda is recalling almost 175 000 cars in the US due to the seats can suddenly change angles, making driving difficult.


And the list goes on.

Wednesday, September 16, 2015

DSG MULTITRONIC TIPTRONIC

DSG MULTITRONIC TIPTRONIC


There is  a common saying that goes something like this, "You can call a dog my any other name, but its still a dog." So whether you  call your Volkwagen, Audi, Seat or Skoda's multitronic transmission a gearbox or call your Direct Select Gearbox a transmission, it is still the same DOG, even though it is spelt DSG. The 02E Direct Shift Gearbox (DSG) is known  as the S-tronic 02E twin-clutch gearbox in Audi circles, and this 02E VW, Audi, Seat, Skoda – Multitronic DSG / CVT Transmission has a fully fledged Electronic Controller (TCM / TCU) onboard-- internal. Because of this, virtually all automatics and semi-automatics, wheter S-Tronic, Mechatronic, Multitronic, Tiptronic,  Continuously Variable Transmission (CVT) or a Direct-Shift Gearbox (DSG),  seems to be extremely troublesome. In fact VW,  Audi, Seat, Skoda owners have so much transmission trouble that in VAG circles it is notoriously known as DOG common. transmission trouble vary from difficulty with the gear selector lever, to stripped gears, to a stretched CVT chain, to faulty solenoids, all of which can cause the transmission to enter emergency mod a.k.a limp-home mode and present you with a flashing P R N D S display or a permanently lit reverse image display.  



In certain cases some of these faults may be corrected by simply renewing the Gearbox oil, or even software update but the bulk of the trouble is caused by the aforementioned Transmission Control Module (TCM), which is also also known as the Gearbox ECU or the Transmission Control Unit (TCU). A faulty Transmission Control Module (TCM) can cause a number of  faults ranging from an intermittent fault that  progressively gets worse.  It can cause the gearbox not to go into gear or to automatically go into neutral or loose power, or stop working when it gets hot. At times the Transmission Control Module (TCM) may be faulty yet not turn on any warning lights and the only way forward, is to scan the TCM to locate the problem.

"DOG COMMON" DSG DIAGNOSTIC TROUBLE CODES.

18223 P1815 Pressure Control Solenoid 1 (N215) Short to B+
18227 P1819 Pressure Control Solenoid 2 (N216) Open / Short to Ground
18228 P1820 Pressure Control Solenoid 2 (N216) Short to B+
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

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+

18222 P1814 Pressure Control Valve 1  - (N215) Open / Short to Ground
18226 P1818 Pressure Control Valve 2  - (N216) Electric Error
18238 P1830 pressure control valve 4  - (N218) Short to Plus

17106 P0722 Gearbox Speed Sensor 1 G195 No Signal
18201 P1793 Gearbox Speed Sensor 2 G196 No Signal
17111 P0272 Rounds Count Signal From Engine ECU, No Signal
17090 P0706 F125 Drive Position Sensor Signal Implausible
17134 P0750 Control Valve 1/Solenoid Valve (N88) Function Disturbance
17137 P0753 Control Valve 1/Solenoid Valve (N88) Electric Error
17114 P0730 Gearshift-/ Transmission Surveillance Wrong Gear Ratio
19143 P2711 Unexpected / Implausible Mechanical Gear Disengagement

The 6-Speed Direct-Shift Transmission (DSG) with Mechatronic J743 shares the same construction of a manual transmission but has the operation of an automatic transmission and fitted into the New Beetle, Golf, Golf R32, the Touran, Audi and so many other models, especially matched to the 2.0L TDI and 2.0L TSI Engines. 

SOME DSG UNITS

02E 300 041 N
02E 300 041 R
02E 300 042 Q
02E 300 046 D
02E 300 046 F
02E 300 046 K
02E 300 146 D
02E 300 146 F

02E 325 025 AD
02E 325 025 AD Z01
02E 325 025 AD Z02
02E 325 025 AD Z03
02E 325 025 AD Z04
02E 325 025 AD Z05
02E 325 025 AD Z06
02E 325 025 AD Z07
02E 325 025 AD Z08
02E 325 025 AD Z09
02E 325 025 AD Z0A
02E 325 025 AD Z0B
02E 325 025 AD Z0C
02E 325 025 AD Z0D

02E 927 770 AD
02E 927 770 AE
02E 927 770 E
02E 927 770 AJ
02E 927 770 F
02E 927 770 G
02E 927 770 L
02E 927 770 M

02E 927 777 D
02E 927 777 OE
02E 927 777 OF
02E 927 777 OL
02E 927 777 OM

The cost of repairing  a DSG Gearbox ECU can easily set you back a good $1200.00 or more, and this  excludes  the cost of reprogramming (coding) the TCM, even though it is a fairly simple repair. The most common transmission problems are solenoids that get stuck in an open or closed position because  the transmission oil isn't replaced at the proper intervals, which then loses its viscosity and because of the heat, hardens between the valve body and the solenoid piston (plunger) causing it to seize.  When this happens the solenoid winding burns out or becomes high resistive. If the transmission oil is replaced as regular as it should, it will in fact lubricate the solenoid plunger (piston) and not get stuck. Problem is, the 7 litres of oil is also quite expensive but rather cost of the oil than an expensive TCM replacement and downtime of the vehicle.
The other problem is the engine heat and the gearbox heat and the transmission oil heat affects the wiring in the enclosed TCM, resulting in the ribbon cable becoming brittle which needs to be replaced when ever the TCM is serviced. The Gear selector switch also have several solenoids that could make you think that the transmission module is faulty even though its not. Its probably best to test all the solenoids before deciding to take out the gearbox.