How the DSG gearbox works

[Blue103TDIDSG]

Ever wondered how the DSG gearbox worked ?
I don't mean the flappy paddles - what's inside the gearbox and how is it all arranged ?

OK....from the blurbs......concentric dual clutches..........dual input shafts - one for odd gears the other for the evens
All sounds too simple

I've rebuilt gearboxes in a previous life but I'd love to know how they physically put these things together .....

Found this video on YouTube...............couple of seemingly "clowns" but stay with it and all is revealed
Verrrrrrrrrrry clever. ..........makes the conventional clutch and gearbox look quite "old hat"

https://www.youtube.com/watch?v=mj1Vk7SE-TI

BTW I've posted this in the Yeti forum as well

[Umai Naa!!]

I expected more witchcraft and sorcery, to be honest.

[Blue103TDIDSG]

I expected more witchcraft and sorcery, to be honest.

Me too, in a way
I had the concentric clutch bit sort of worked out in my head (with the help of a couple articles I read)
unfortunately could never find any diagrams
But the dual input shafts had me tossed - for some reason I was trying to see them side by side not end to end
Obviously the end to end stacks up with the concentric shafts - pardon the pun
Much greater brains than mine put this together !!!
Just nice to see VW using this technology
I will never be able to afford the likes that usually have them

[Darwinite]

DSG gearbox error

Hi there, this is amazing! Thanks for posting the video.

It explains, from what I got out of the video, why my DSG gearbox just this weekend only engaged every 2nd gear. It is a 2014 MK7 TSI 1.4L Golf (26,000km).

It's in service now ...

Cheers

[Sunny43.5]

And for all this wonderful technology you will pay a fortune when it goes bung , I spoke to an auto transmission shop and they refused to work on them .

[Umai Naa!!]

Until recently, there was barely any repair documentation on them.

However, there's plenty on replacing the clutches and Mechatronics unit, which are the usual culprits.

[asa572]

And for all this wonderful technology you will pay a fortune when it goes bung , I spoke to an auto transmission shop and they refused to work on them .

Maybe because they aren't an automatic trans!

Aren't the gearboxes (mechanical parts) pretty much bullet proof?

I just got my 195k DSG serviced today, shifts as good as the day I bought it at around 100k.

I love em!

[Umai Naa!!]

7-speed dry clutch DSGs were the most problematic.

Have heard of internal bearing failures on the 6-speed wet clutch ones, but not that common. Have driven a few with well over 200,000kms on them, and yeah pretty much faultless. Just throw oil and a filter through them every 60K, and keep on motoring. Same can't be said for the conventional autos VW were using. Ticking time-bombs.

[gldgti]

7-speed dry clutch DSGs were the most problematic.

Have heard of internal bearing failures on the 6-speed wet clutch ones, but not that common. Have driven a few with well over 200,000kms on them, and yeah pretty much faultless. Just throw oil and a filter through them every 60K, and keep on motoring. Same can't be said for the conventional autos VW were using. Ticking time-bombs.

Its all VAG groups servicing recommendations I reckon. ZF state all their gearboxes should have fluid changed every 80,000 miles and sooner depending on conditions of useage... VW and audi say filled for life.
Its not the gearboxes fault

[asa572]

Same can't be said for the conventional autos VW were using. Ticking time-bombs.

Had a mk4 Golf auto hand grenade while teaching my son to drive.

[Umai Naa!!]

I've serviced a few before or at 60,000kms. A couple of years later, they've carked it from valve body failures, shredded brake clutch discs (equiv: bands), baked internal wiring harness, etc.

Look at all the MK4 Golfs, and T4 Transporters on Ebay going cheap with blown autos. I wouldn't entirely put it down to a lack of oil changes. Sure, servicing helps, but it's not always the determining factor.

[Sunny43.5]

Thanks Umai you are spot on as usual , seems that VW did not bother to do any sort of checking on Australian climate and driving conditions before unleashing their technology on us to test in the real world . If our T5 Tipronic had been serviced at 60000 when I asked the local dealer because of an issue with it , I would not have had to spend $8500 later to have it rebuilt just because VW had an internal filter which became blocked with decayed fluid and clutch particles .