R36 DSG Clunk

[platzie]

Hey everyone,

Wondering if there’s anyone out there who has had a similar problem to me and might be able to provide some info.

When the car is cold everything seems to be fine. However when it’s hot, engaging and disengaging drive and sometimes reverse produces quite a noticeable clunk noise and sometimes is enough to be able to feel it through the car.

From what I’ve read on these forums DSG’s seem to typically make some weird noises here and there, and I’ve read of people experiencing a similar clunk noise when changing gears. Mine however changes gears fine it just seems to be when switching between drive, neutral, and reverse while hot that the problem arises.

Thanks again to anyone who may be able to help.

Cheers.

[kamold]

How recently was the DSG fluid/filter changed?
This is generally the first port of call for all things DSG.
Replace the fluid and filter, make sure basic settings are run on the transmission with suitable diagnostics software which will adapt the clutches etc, then see how it goes.
If the issues persist then you have to start looking towards mechatronics replacement or a rebuild/replacement of the transmission.
Mine can be a bit clunky going between forward and reverse gears. Shifts beautifully up and down through the gears though since the most recent fluid replacement and adaptation.

I tend to pause for a few seconds after shifting between a forward and reverse gear before applying any throttle to allow the transmission to perform it's change.
If mine starts to misbehave any more seriously than the occassional clunk as it does now I'll look at getting the mechatronics replaced as this is relatively straight forward, though still not cheap.

[platzie]

Thanks for the reply. DSG fluid was replaced less than 12 months ago but I’m not sure about the filter, I would assume it was done too.

I’ve been reading about the DSG adaption I might see if VW can do this at its next service.

Same with me I pause and wait until I can feel it’s engaged before taking off. Fingers crossed it’s not a big issue but just thought I’d post on here to see if anyone else has experienced this.


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[Felixrising]

How often is yours doing this? I also have the occasional clunk. I also am noticing more gear whine noise (hoping its not a failing bearing... but apparently 4-motion DSG is often quite noisy and maybe I'm just paranoid? )

As @kamold mentioned, changing Fluid and Filter and running the Basic Settings is probably the first port of call. If you had the DSG fluid changed recently, then they would typically do the filter at the same time (it would be piss poor if they were so lazy not to change the filter during the fluid change). Note that DSG fluid change is every 60k kms during normal usage for the Australian market, but in other markets and under harder use, service intervals should be more frequent - say every 45k kms.

You might find it cheaper going to a VW/Audi specialist - VW Service Centres are not cheap! (caveat! only VW will have firmware for ECU/DSG etc)

If you get into mechatronics changes, there may be an option to source a reconditioned unit which typically works on a exchange/swap basis (you send your old unit to them for reconditioning and they send you a already reconditioned unit). You'll note that dual mass flywheel (DMF) and clutch packs are other items which can require replacing.. and hopefully less often, bearings.

There are a few other good articles around on the DSG/02E DQ250 in our R36s...
Highly recommended reading (heaps of diagnostic info): VW 02E DSG Gearbox DQ250 , DQ500 , DQ501
Common Faults in the 6-Speed DSG Automatic Transmission | AxleAddict
A further look at the DSG | Search Autoparts

[platzie]

It clunks pretty consistently when the engine is hot, more often than not. I’m assuming when it’s cold the higher viscosity of the oil dampens the clunk enough that it can’t be heard or felt.

I’ll definitely look in to getting the adaption reset done. I could very well be wrong but I would have thought if it were the mechatronics failing the problem would be evident in other aspects of the drive too, like clunky or slow gear changes. Whereas as far as I can tell every aspect aside from actually engaging and disengaging D is seamless.

Thanks for digging up those links for me I’ll give them a read through .

Cheers


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[Old Navman]

How often is yours doing this? I also have the occasional clunk. I also am noticing more gear whine noise (hoping its not a failing bearing... but apparently 4-motion DSG is often quite noisy and maybe I'm just paranoid? )

As @kamold mentioned, changing Fluid and Filter and running the Basic Settings is probably the first port of call. If you had the DSG fluid changed recently, then they would typically do the filter at the same time (it would be piss poor if they were so lazy not to change the filter during the fluid change). Note that DSG fluid change is every 60k kms during normal usage for the Australian market, but in other markets and under harder use, service intervals should be more frequent - say every 45k kms.

You might find it cheaper going to a VW/Audi specialist - VW Service Centres are not cheap! (caveat! only VW will have firmware for ECU/DSG etc)

If you get into mechatronics changes, there may be an option to source a reconditioned unit which typically works on a exchange/swap basis (you send your old unit to them for reconditioning and they send you a already reconditioned unit). You'll note that dual mass flywheel (DMF) and clutch packs are other items which can require replacing.. and hopefully less often, bearings.

There are a few other good articles around on the DSG/02E DQ250 in our R36s...
Highly recommended reading (heaps of diagnostic info): VW 02E DSG Gearbox DQ250 , DQ500 , DQ501
Common Faults in the 6-Speed DSG Automatic Transmission | AxleAddict
A further look at the DSG | Search Autoparts

Ross Tech page states that apart from the Basic Settings the VCDS can perform (on 6-Speed Direct Shift Gearbox (DSG/02E) Transmission Tolerances (Engaged Calibration), Transmission Tolerances (Synch. Point. Measurement), Clutch Adaptation, etc.
It would seem that IF you have the Ross Tech cable/software or similar you can perform the above tasks yourself? (as distinct from firmware change/upgrade) I'm not sure about the R36 vehicles but it would appear likely that this can also be done outside the VW/specialist environment (as in DIY)?

[kamold]

Yes you can run basic settings with VCDS yourself. It will walk you through the procedure.

[Old Navman]

Thanks kamold, perhaps you can walk us through for platzie's but also other's benefit. Cheers

[kamold]

Thanks kamold, perhaps you can walk us through for platzie's but also other's benefit. Cheers

Felix rising already shared a link to the wiki on the Ross Tech website. (First link)
This takes you through the procedure.

[Felixrising]

This one:

http://wiki.ross-tech.com/wiki/index...rbox_(DSG/02E)

[snerlo]

Going out on a limb here. Have you had someone check the engine mounts as well as the gearbox mounts (if there is any as I'm not a super mechanic). Mine was generally changing gears fine but didn't have any clunking, but I was told that one engine mount needed replacing. Upon picking car up from service, the gear changes and everything was genuinely smoother. Get these checked out before panicking too much about mechatronics and everything else.

[platzie]

Hi all,

Just thought I’d give an update.

We asked VW to have another look at it and insisted they try to diagnose the problem as it had been getting worse over the 12 months.

They ran the codes and got no faults, reset the gearbox back to basic settings and the problem persisted.

They sent it off for technically analysis and came back and suggested the clutch pack needed replacing so we went ahead with that. Just picked up the car yesterday and the problem is fixed!