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DSG box service. DSG gearbox is what it is. How to use DSG box

Robotic mechanical transmissions manufactured by Volkswagen received a wide range of recently. DSG abbreviation means nothing but a robot box produced by VW. Such units are installed in the cars of the Audi brand, however, this firm uses another name: S -tronic.

Ultrafast gear shift in a robotic box On the one hand, it helps to achieve good dynamic characteristics. But at the same time, the greater the steps are used (6 or 7), the more "gentle" and the demanding in operation it turns out the node itself, that is, a robot box. In 7-speed DSG, in addition, dry clutch is used. What limits their scope by motor with a small torque value.

The clutch disk function to each other in the "robot" mechanisms are performed, the general name of which is mechatronics. The main advice that avoids the overheating of the mechatronics with the subsequent breakdown, it sounds simple: stopping longer than a minute, it is necessary to include "neutral".

That is, standing on the traffic light, you can not touch the PPC knob. But getting into the plug, it is better to include neutral transmission Moreover, immediately. Without forgetting to move at the beginning of the movement to "M" mode (manual control) or "1".

How often does oil change in DSG boxes? The answer to the question depends on the type of transmission design. For example, 6-speed DSGs are designed to replace the oil every 60 thousand km. Together with the liquid, the filter must be replaced. It is quite logical that oil replacement is required for DSG with a "wet" clutch.

DSG transmission of any design - has a clear limit on the maximum torque torque Supposed to it. This requirement is often disturbed when the engine is replaced with something more powerful. And even the usual "chip tuning" of the motor - entails a premature failure of any DSG box.

It would seem that good in a robot box? It is more complicated to exploit it than the usual ACP, and some requirements are specific. In fact, robotic mechanical transmission provides maximum efficiency and best dynamics immediately. Here, energy is transmitted practically "without loss", and DSG transmissions switches faster than most drivers.

Modern motor vehicles, in pursuit of comfort, convenience and safety of driving, are increasingly equipping the technique developed by complex systems and devices. No exception and transmission mechanisms. DSG gearbox is currently considered the most technological and advanced among the products of this kind.

The abbreviation itself is decrypted as "Direct-SHIFT Gearbox", literally "direct gearbox". The technology received an impetus in its development due to the Volkswagen concern, who released the six-speed DSG 6 gearbox model, and a little later upgraded seven stepped version of DSG 7. Both of these boxes have become a real breakthrough in the automotive industry, they sold more than a million pieces and demand does not fall. However, despite the technical and technological innovations, as well as any other mechanism, the automata have positive and negative sides.

Varieties of boxes

At the moment there are two main ones working on the DSG principle. Both options are widespread and used on motor vehicles manufactured by the Volkswagen Audi Group). This is a DSG 6 gearbox and its more modern version of DSG 7. Mechanisms are installed on well-known and popular cars: Volkswagen, Skoda, Audi, Seat.

Both gearboxes use the same principle, however, there are many differences in their designs. Thus, the main feature of the DSG 6 box, compared to DSG 7, can be considered the use of adhesion with the friction part placed in the oil bath, which allows to significantly increase the product resource. In such a bath, disk packets are lubricated and cooled, it has a favorable effect on the mechanism.

Due to its design and good cooling, DSG 6 provides a traction force up to 350 nm, which makes it an ideal candidate for installation on cars with powerful motors. The gearbox is installed on the engines with a volume of 1.4 to 3.2 liters.

The most famous models that use the DSG 6 version (DQ 250):

Volkswagen: Passat, Golf, Scirocco, Sharan;
Skoda: Octavia, Yeti, Superb;
Audi: A3 8V, TT, Q2, Q3;
Seat: Altea, Leon, Ateca.

Since not all car models need a powerful gearbox, such as DSG 6, the developers designed, an improved box with seven DSG steps 7. In addition to the number of steps, the distinctive feature of this DQ200 DQ200 box was the use of clutch with a dry friction part, the gearbox was designed Especially for power plants, with not exceeding a value of 250 nm.

By comparing the sixth model with the seventh, you can highlight the benefits of the latter:

The box needs fewer lubrication (1.7 liters. Against 6.5 liters in the sixth);
Little weight and dimensions of gearbox (70 kg. Against 93 kg. In DSG 6);
High fuel savings, by eliminating losses on the pump drive for oil.

The characteristics of the robotic gearbox fell to the consumer, thanks to this, it was widely used on low-power units.

The DQ 200 robot is installed on such cars:

Audi: A1, A3, TT, Q2;
Volkswagen: Golf 6-7, Polo, Passat CC, Touran;
Skoda: Octavia A7, Rapid, Fabia, Karoq;
Seat: Altea, Leon.

Due to the fact that the friction part of the clutch in the DSG 7 gearbox was dry, its installation to more powerful power units has negatively affected the reliability of the mechanism. Late box designs received "wet" clutch and could be installed on powerful motors.

The most popular version of DSG7 0DL DQ500 was used in models:

Volkswagen: Passat B7, Tiguan, Arteon;
Skoda kodiaq.

There are still many modifications of DSG 7 boxes, in the design of which oil bath is used, most of them are intended for use on vehicles manufactured under the Audi brand.

DSG device and principle

From the point of view of the design, the robotic box automatic DSG 6 and DSG 7 is a mechanic, however, in contrast to it, there are no power losses when switching the speeds, and there is no break between the transmissions. Thanks to this decision, at the time of switching, the engine does not work in idle, which guarantees a car high dynamics during acceleration and substantial fuel savings.

Application in the design of two clutches is a factor that distinguishes the mechanism from any other box. The principle of clutch operation is based on the fact that switching gears in DSG 6 and DSG 7 occurs simultaneously with the turnsuit of the first clutch and the inclusion of the second. This contributes to a torque on the wheels of the car is uninterrupted.

Primary shafts, as well as clutches in the design, two are applied. Based on all above, it follows that DSG technology is nothing more than two mechanical boxes running synchronously. The first box serves even drives, the second box is responsible for odd switching.

Starting the movement, the first and second transmission are synchronously turned on, the adhesion on the second transmission remains in the open position. When you need to go to increased gear, the first clutch is simultaneously opened and the second is turned on to operation. This principle of operation DSG is applicable to all transmissions used in the box.

The operation of the device occurs automatically, but in contrast to the classic machine in it there is no. The name "Robotic Gearbox" was given to avoid confusion in the classification of mechanisms.

Robotic gearbox includes the following items:

Clutch coupling consisting of multiple disks;
Pulley (primary);
Pulley (secondary), 2 pieces;
Variable gearbox case;
Mechatronic, device control box.

MEChatronic block, this is a combination of various sensors and electronics. His task, track readings responsible for the frequency with which the shafts of the box at the inlet and outlet of it rotate. In addition, the block takes into account the temperature and pressure of the oil, the position of the scenes.

The block consists of:

Hall Sensor;
Electro-hydraulic control device;
Transmitting wires;
Devices executing user commands.

There are no special instructions for using DSG boxes. The transmission is automatic, the user intervention in its operation is minimized, so it is almost impossible to affect the resource of the gearbox in the direction of increasing or decreasing.

There are a number of rules, observing which you can renew the box work to its repair, even if indirectly.

Switching transfers, squeeze the brake must be stopped. Weak pressing does not allow you to completely open the disks and leads to their wear;
If the stop does not exceed one minute, you should not switch the scene into a neutral position, it is desirable to use the "S" mode in the plugs and move in rolling;
It is not recommended to trim from the place using slipping;
Handbrake must be installed without letting the foot brake pedal;
Modes need to be switched smoothly, with a small pause between switching;
For a DSG box 6, a timely replacement of oil plays a significant role, it is necessary to change it in a filter complex, every 60000 km;
If the machine is stuck or bonded in the mud, freeing it, the gear shifting is needed to neutral.

It may seem that the DSG box imposes many restrictions on the operation of the vehicle. Stopping your choice on it, the driver gets comfort and safety, and this is important.

At the moment, modern DSG model shift shift boxes are the most advanced automatic gearbox. They differ significantly at the price of the usual "automata", and, in a smaller side. Robotic DSG gearboxes are installed on all brands of cars of the Volkswagen concern, gradually squeezing out ordinary models from the market. According to its own principle, they are an analogue of a mechanical CP, however, during shifting the gears, they work in the same way as automation - using a computer program implanted into a special control unit.
The main feature and advantage of this approach lies in the innovative technology, which allows you to switch the transmissions, practically non-losing the engine power parameters at this point. Of course, in this case, the efficiency of work and comfort is significantly higher, however, as well as a sense of a car during a ride. The secret of success in the double clutch system, which allows not to rotate the torque during switching, thereby making the direct transition between the transmissions almost inconspicuous, both for the engine and the driver.

It is worth noting that at the moment DSG 6 is not the last model of the entire row of robotic boxes from Volkswagen. The DSG 7 version is also released - seven-step gearbox. Two models differ from each other with maximum torque indicators. So, the seventh series can develop torque mainly to 250 nm, which makes it possible to install it on budget cars. At the same time, the sixth model is considered more powerful (up to 350 nm) and is installed on larger and most powerful cars, most often premium class. Of course, the power of DSG 6 lacks for work on large SUVs, where Volkswagen most often install "automata" with eight steps.

6 Step DSG consists of several devices:

two rows of gear;
double grip;
differential;
carter;
system control unit;
lavar gear.

How does a robotic DSG box work

The device of a robotic box from Volkswagen is too simple cannot be called, but, in fact, most of the principles of its work are based on ordinary mechanics with elements of the "machine".

Double grip is the main catalyst for transferring torque into two rows of gear. The drive disk is started due to the clutch. With flywheel and friction clutches, it connects a special hub with a mounted flywheel, which also combines each of the transmissions each.

The DSG 6 automatic transmission has a "wet" clutch, which, regardless of whether it works or not, should be in sufficient oil. Note that it is because of this, a six-speed box requires more oil to work correctly (about six and a half liters) than seven-step (only up to two liters). This is due to the fact that DSG 7 is equipped with a "dry" clutch, for which a significantly smaller oil is needed. It is impossible not to say that with this state of affairs, the "six" is less effective, since it has a hydraulic pump for oil, and not electrical, like its "younger sister".

As we have already spoken above, two rows of gear are used in the design. The first row works exclusively with odd gears, including rear. The second number is responsible for the correct operation of even gear. So, each of the rows works in a bundle, representing two shafts with gears.

One of the most important elements of the box is an electronic control unit. It also consists of several parts:

sensors allowing to collect data from car systems;
electronic "filling" managing everything through a computer program;
hydraulics;
mechanisms responsible for the execution of commands of the control unit.

The control unit is located in the crankcase itself (the main body of the gearbox). All hydraulics and electronics are located in one special block, known as a mechatronics. Sensors receiving signals from other car system is also in a block with electronics and hydraulics.

Input sensors are needed in order to read the data on how rotation is rotated at the output and the input of the KP. They also check the oil temperature, the level of pressure and whether the plugs of the box are correct. The electronic unit receives all the information from the sensors, after which it uses one of the cycles that are laid in its main gearbox control program.

If we talk about the electro-hydraulics, which is the second most important element of the DSG 6 control, it responds to the adjustment of the hydraulic circuit of the KP. If you dig deeper, then several main components of the electro-hydraulic unit can be distinguished:

electromagnetic and adjusting valves (the second is responsible for the pressure level);
distributing spools;
multiplexer issuing the primary control signal box.

As soon as the selector begins to move, the distributors come into operation. Shift shift is carried out using solenoid valves. Pressure valves allow you to correctly adjust the friction clutches. Thus, the valves in the DSG 6 box can be safely called the main executing elements providing the main principles of operation of automatic transmission.

A multiplexer remains, which is engaged in the control of hydraulic cylinders. There are eight of them, but at the same time not more than four valves are used. During the transition of the multiplexer to the various mode, different cylinders are in the working bundle. But, there are always only four - all at the same time, no with what mode, it will not work.

Thus, it can be understood that the DSG 6 gearbox operates on relatively simple algorithms that are cyclic. At the same time, two rows of gear are used. Starting the first, you immediately start the second, which until the switch remains in an inactive position, however, during the transmission switching, it does not start again, and simply goes to the active phase, thus reducing the time to switch up to several fractions of a second.

It is necessary to understand that DSG, both six and seven-step gearbox, is a relatively new models of transmission. Let the switching occurs in automatic mode, it is impossible to say that it is a familiar "automatic" or even something close to it as much as possible. Therefore, there are a number of rules that should be known by car drivers with a robotic gearbox. Compliance with them will allow you to increase the service life of the system and protect it from breakdowns. It is extremely important, since the repair of DSG 6 is not cheap pleasure.

Switching on various cars with such a box, including Tiguan and Golf, pretty tough, if you want to change the ride style sharply. Such behavior of drivers is often found in the conditions of urban roads, but, a sharp style shift should be avoided, as it can quickly wear the box of the box. It also makes sense and in winter, when the car can start, without progressing - in this case you need some time to move very carefully, without breaking off or sharply induce the brake pedal.

Regarding maintenance you need to remember that changing the liquid and filters in the DSG 6 are needed at least once every 60,000. We note that saving on cheap liquids can lead to a rapid output of the box. It often happens that once saving, the driver has to change not only the mechatronics DSG, but also almost all automatic transmission systems, which is quite comparable to buying and installing a new "machine".

I remember everything that we wrote above can really improve the operation of the box and significantly increase its life. The main thing is not to forget about the careful handling of this system.

Oil change in DSG 6

Finally, briefly tell about how the oil is replaced in the DSG boxes. The process looks unusual, although the complexity is no different.

Mechanics use a special large syringe designed to work with robotic boxes. The gearbox oil is poured below, after checking the oil for chips. It is noteworthy that self-replacement of oil in a robot box is almost impossible without special tools.

The effect after they change the oil, very tangible. If you ride with DSG at least a year, then after replacing the feeling is created that you are literally a new gear shift system. The machine moves much more smoothly, and various brackets and twigs, which sooner or later may appear during the operation of the DSG 6, disappear after replacing the oil for a long time.

Preselerative box - a two-clutch robot is placed on many models issued by the Volkswagen concern, while you can meet as an earlier version of the DSG-6 and DSG-7.

As practice shows to maximize the DSG service life, it is necessary to consider certain nuances during the operation of the PPC of this type. In this article we will look at how to properly use such a gearbox.

Read in this article

How to use DSG box

Let's start with the fact that DSG provides excellent acceleration dynamics and fuel efficiency inherent, as well as comfort. As a result, the preselative robot has become one of the most promising types of PPC.

At the same time, even taking into account the similarity with the automatic transmission on the principle of operation, as well as with the manual transmission, the operation of the car with the DSG is somewhat different from the machine, mechanics and simple single-robots (AMT gearbox).

Moreover, some nuances arise even depending on which type DSG is installed on a specific car model. For example, the DSG-6 box is "wet" (operating in the oil bath), while DSG-7 is "dry".

In this case, the clutch discs, both in the first and in the second case west, and in the case of the DSG-7, it happens faster. This means that aggressive ride style, sharp accelerations from space, slip, etc. For DSG-6 are still allowed, but this cannot be said about DSG-7.

The fact is that the grip in the oily bath is more protected from wear and overheating than its "dry" analog. Also, DSG-6 was originally designed for a larger torque (about 350 nm), while the version of 7-steps "digested" is not more than 250 nm.

In practice, this means that harsh exploration will quickly bring DSG-7 in order. Cases should be mentioned when such a gearbox did not care more than 50-70 thousand km. Since the purchase and required expensive repairs.

It is important to understand how to use DSG in traffic jam and operate the machine with this box within the city. First of all, in order to save fuel, the DSG in automatic mode usually quickly switches from the first to the second transmission. At the same time, if the driver is on the brake or not accelerates, the transition to the first speed again.

It turns out that with such a ride "jerks" there is an accelerated wear of the box and clutch, the clutch overheats, etc. To avoid this, optimally switch to manual control using a semi-automatic mode of the box. If simply, the driver independently includes the first gear and does not switch to the second, if this situation has developed on the road.

More in the list of rules that can increase the DSG resource, you should select the need to actively press the brake pedal when switching modes. In the event that the brake is not completely squeezed, the DSG does not fully open the clutch discs, thereby increasing wear.

Also, the transition rule to the "neutral" when stopped, relevant for "one-piece" robots, to a lesser extent affects the DSG. In other words, switch to N on traffic lights and during downtime to 60 seconds. No need, since frequent switching only increase wear. Moreover, with a fully press brake, the box itself opens the clutch.

You need to know that the DSG box (especially 7-step) is "afraid" slipping even more than automatic transmission. This means that to stop in the mud, on ice, when starting from place in manual mode, etc. prohibited.

Also, when setting in Parking regime, you need to use the parking brake to extend the service life of the limiter (blocking mechanism), which prevents the car rollback. Switching between modes must be smooth, with a slight delay of about 1 second. During this time, the electronics will fully manage to "fit."

It should be added that the car with DSG should not be overloaded towing the trailer or other transport, as well as transportation of various goods in the car itself. In practice, initially heavy machine with DSG-7 (for example, Skoda Superb) with a full cabin of passengers and an additional cargo can weigh about two tons. Taking into account the fact that the box is not designed for heavy loads, such a robot may unexpectedly fail.

As for the DSG-6, this PPC is more worn and installed in a pair with powerful engines. However, this does not mean that the machine with such a transmission can be constantly used as a tug.

First of all, the DSG box needs maintenance, and more often than manual transmission. For example, in DSG-6, the clutch works in oil, the volume of lubricating fluid itself is quite large.

For this reason, the oil change in the DSG should be made every 60 thousand km. Run. In parallel, the gearbox filter changes. At the same time, without proper experience and equipment, it is better to abandon self-substitution in a garage.

We also add that if the machine with DSG is stuck in dirt or snow, you need to refrain from intensive attempts to go to the star. It is better to translate the box to N mode and use a third-party help, that is, pull out or pour out the car.

If there was a need for DSG, you need to adhere to the rules and recommendations, towing the machine with permitted speed and only for short distances. Information is usually contained in the manual.

That in the end

As can be seen, the operation of DSG quite strongly resembles the use of a classic hydromechanical automaton of automatic transmission. At the same time there are differences. For example, DSG allows you to switch from mode D to R without a small delay in N. However, it concerns the slip, the robotic transmission to them is most sensitive.

It should also be borne in mind that a robot with two clutches is a rather complicated unit in terms of construction. At the same time, in comparison with other types of transmission, the repair DSG is often obtained not only costly, but also problematic. The reason is not every car service capable of repairing DSG qualitatively.

As a result, we note that even taking into account all the difficulties and potential problems, the DSG box is still the most preferred option when choosing a new car.

The manufacturer of VAG itself is constantly finalizing the design, makes changes to the PPC operation algorithms, improves the firmware of the electronic unit, etc. As a result, you can count on improving reliability and a sufficiently long service life of the gearbox.

How to manage DSG in traffic

Do not put the selector to N. Now modern robots tear the clutch simply when you press the brakes (come out of the engagement). That is, the car under the brake is pressed - it stands on a neutral.
No need to move on half a meter pressing gas - brake. (Each time I have releasing the brake - you seem to let the clutch, it automatically begins to touch the flywheel, as well scrolls due to incomplete contact. When you released the brake and eat at a speed of 5-6 km / hour, then there was a complete gearing).
Release ahead of the car meters ahead of 5 in front of you and move behind it at low speed, on the first gear.
DSG resource 6 and DSG 7directly depends: whether the robot will switch to the second speed in the traffic jam. Switching the first is the second, the second - the first in the traffic jam "kills" (the clutch and flywheel is worn out and overheats) any robotized box with two clutches.

How to brake on DSG

When you go rolled, the clutch is rigidly connected with the flywheel. If at this moment pull sharply on the brake, the load from the rapid reduction of speed goes to the box. The clutch does not have time to open and on the flywheel are formed. Subsequently, DSG begins to tremble and twitch. A common example is a sharp reduction in speed in front of the traffic light.When moving, rolling smoothly press the brake, let the clutch quietly open.

How to use manual mode

On robotized gearboxes in most cases there is a manual mode. The catch is that the automation does not fully understand what kind of transmission you want to enable (upstairs or down). If you press gas - the box is preparing increased, if you slow down the opposite is reduced.

What happens if you do it on the contrary. Suppose you go to 4 gears and smoothly accelerate. Automation prepared for inclusion 5 transmission. But you go to the third. At this point, the box has to change the prepared speed to reduced. Switching occurs in fact (as on one disk robot). On a small gas, this operation is not dangerous. But if it is wrong to switch to intensive driving around the city, there is an intense wear of the flywheel. What keeps everything to the same vibrations and "twigs".

Start with two pedals

Modern producers have already made "fool protection" and taught automation not to react to such manipulations when the brake pedal is pressed.

If you do not want to kill your box - do not do it. Especially if this box is with dry clutches.

In order to quickly accelerate just sharply click on the gas pedal.

DSG is not calculated

If your car has no capacity. Most likely you have a dry clutch box. This box is not designed for racing from traffic lights to traffic lights. Her task saves you fuel.

On DSG 7 dry clutch and there is no additional cooling. All cooling in this node is the heat capacity of the clutch and flywheel. And if you start to drive, then this cooling limit will come very quickly. DSG is designed for quick acceleration, as without them. To extend the box resource, follow the ratio of 3 to 1m.

Five minutes to blame, fifteen ride calmly.

Well, do not think that at any moment she cracks - here is the resource tests from the autores:

I hope this article on the correct operation of the DSG was useful to you !!!