Clutches and gearbox units are operated hydraulically. This function is performed by the gearbox mechatronics, housed in the DSG. The term “mechatronics” is derived from a combination of mechanics and electronics. And this is exactly how the mechatronics module is structured: the electronic transmission control unit, various sensors and the hydraulic control unit form one compact unit.
The control unit uses information such as engine speed, road speed, accelerator position and driving mode to select the optimum gear and to determine the ideal shift point. The hydraulic control unit then implements the shift commands in a complex sequence of individual, precisely coordinated actions.
Two clutches – eleven sensors – one control unit
The double-clutch transmission consists of two subgearboxes, each with its own clutch, that work together to shift the gears. The integrated electronic control unit that Temic developed for this transmission comprises 11 sensors and 11 actuators (e.g. valves) in one single component whose main function is to open one of the clutches and to close the other at the right moment. This results in smooth shifting without interruption of the tractive force. The electronic unit processes the sensor signals, measures the rpm’s, the speed and the load on the transmission, ascertains the positions of the mechanical components and electromagnetically operates the valves and slides of the hydraulic gear mechanism.
Such highly integrated mechatronic parts are only possible with the use of high-performance engineering plastics: Only a material that can be freely shaped is able to protect the electronic components while combining actuation and sensor technology in an extremely small space and in a single part. The wiring is simplified, the number of cables and plugs is drastically reduced, and interfaces are rendered unnecessary, thus yielding a component that is small, lightweight and reliable.
One plastic – two uses
Ultradur® B4300, a PBT made by BASF, fulfils a number of mechatronic functions in the control unit produced by Temic. The standard variant, B4300G6, containing 30 percent glassfibres, has all of the mechanical and chemical properties, for instance, dimensional stability, needed to withstand hot transmission oil. Semiconductor sensors secured in place with this plastic must not shift their position, even when exposed to high temperatures and oil. In contrast, type B4300K6, which is reinforced with glass beads, has to be highly isotropic, so that no oil can get into the structures. The Swoboda company located in Wiggensbach in the Allgäu region of Germany is in charge of the injection moulding of this plastic.
Thanks for the info.
My Mechatronics unit in my 2008 GTI just went faulty. My GTI is parked while a new one is built in Germany and shipped to NA. The estimate is five weeks and my GTI cannot be driven! This is the third one at my dealership so I’m not sure if they are that reliable yet.
Great thanks
Cool blog
My GT Sport 170 Diesel DSG has suffered the same – VW UK have no idea when the part will be made, let alone shipped…!!!! That was 3 weeks ago. This must be costing VW a fortune – I have a rubber-mat Golf as a courtesy car which is no replacement for the GT Sport. This was my 3rd VW that has had a catastrophic failure at around one year old. It may be my last…. G
I just got my 2008 GTI back after it sat at the dealer 23 days waiting for a new mechatronic unit to come from Germany. I had the hardest time getting VW to be able to recreate the problem, but eventually one of the mechanics stumbled upon the problem I’d been complaining about for months when I had it in for something else.
Anyway, just got it back yesterday, so we’ll see how it goes. I only have 16,000 miles on the car, now, but the problem began last year!
Guess what – I’ve a dead one as well on a 2009 TDI 140 Golf Estate, 10K miles, but been like it since new. Still driveable at the moment, but clonking and jerky changes that drive you mad! Dealer says 2 week for the part . . .
I have a 2008 MKV R32 and I think that my Mechatronic Control Unit is about to die on me… These are the fault codes I pulled from my car.
———————————–
3 Faults Found:
18270 – Powertrain Data Bus: Missing Message from Instrument Cluster
P1862 – 000 – - – Intermittent
Freeze Frame:
Fault Status: 00100000
Fault Priority: 0
Reset counter: 10
Time Indication: 0
18097 – Powertrain Data Bus: Implausible Message from Elect. Load Controller
P1689 – 000 – - – Intermittent
Freeze Frame:
Fault Status: 00100000
Fault Priority: 0
Reset counter: 10
Time Indication: 0
18275 – Powertrain Data Bus: Missing Message from Steering Wheel (J527)
P1867 – 000 – - – Intermittent
Freeze Frame:
Fault Status: 00100000
Fault Priority: 0
Reset counter: 10
Time Indication: 0
—————————————————
Address 16: Steering wheel Labels: 1K0-953-549-MY8.lbl
Part No SW: 1K0 953 549 AQ HW: 1K0 953 549 AQ
Component: J0527 036 0070
Coding: 0012122
Shop #: WSC 01279 785 00200
Part No: XXXXXXXXXXX
Component: E0221 002 0010
1 Fault Found:
01749 – Switch for Tiptronic in Steering Wheel (E439); Down
008 – Implausible Signal – Intermittent
Well after 2 times at the vw mechanic my 2008 golf gti also has a dead mechatronic control unit, it seems that this so called specialist part which can withstand the environment within which is has been submerged (the trans) is not all that reliable. I’m assuming that seeing as my car is only just over 12 months old im going to be going through a few of these control units. better get it fixed at the end of the warranty and then sell when my 3 years are up haha.
I had mine changed 4 months after I bought the car(brand new). I also needed to CONVINCE the engineers there was a problem (I’m in Greece).
Been 17 months since then, all seems fine.
Warranty ending in 3 months, fingers crossed…
great thanks
I OWN A 08 VW EOS. I REPLACED 1 OF THESE CONTROL UNITS AND WAITING FOR A SECOND. NOTHING BUT TROUBLE FROM DAY ONE. LOVE THE CONVERTABLE BUT THE SAFETY ISSUES ARE TO MUCH. IF IT DOESN’T GET FIXED NO MORE VW FOR ME.
Golf GT TDI 170 8/2008 reg 10,000 miles just bought -1 previous owner bought from a main dealer, 2 weeks and 1500 miles ago terminal failure pulling on to a roundabout – no drive and whole family in the car – could have been terminal for us all!! Not impressed. 3 hrs for VW assistance/RAC to recover (12mth old baby & 6yr old in car) from side of busy dual carriageway in the middle of nowhere. Dealer has had car for 6 days and is now ready to collect. VW very apologetic but I am now concerned about safety and reliability
have a 2007 golfV 1.4TSI 140hp 58000km on the clock, mechantronic failed. shakey gear change, and problematic from 0 to in motion. So problematic that cars near by think I am a new driver trying to use proper half clutch. delay in gettin in motion. No guarantee, dealer says about 2500 Euros for the replacement. Well done VW what a reliable car!
12.2009 VW Golf GT MkV 1.4TSI 170bhp 46,000km – I’m waiting for my new mechatronics module from Germany too. My transmission is jerky, rough and loud when gears change. I experienced a non-responsive throttle once. I remember I had it in manual shift going at around 90km. I floored the gas pedal but the RPM stayed at 3,000. And no it wasn’t in Auto-cruise control. I tried flooring the gas pedal 5-6 times. I had the VW mechanic beside me when it happened and he couldn’t tell me why it was non-responsive. I tried upshifting and downshifting but the gears didn’t change. I put it in Auto (D position) and then back to manual and the problem disappeared. Sometimes the car computer freezes and some things just don’t work. The battery has to be disconnected to solve the problem. I just got my turbo replaced at 40,000km. This car is so unreliable and I’ve wasted almost 2 years trying to solve all the problems this car has. VW mechanics always say “If it isn’t throwing codes, it’s not broken!”
hi Daniel in Taiwan,
What is the cost of the turbo charger that you are replaced.
Thank you.
I know it’s been a few months since your blog, but I just had my turbo & engine harness replaced on a 2009 jetta TDI. In the past month we have put out close to 5,000. Dealership has been reducules!!! Turbo was almost 2,000.
VW must solve this problem in DSG 7 speed gearbox, more than 6 cases ( deffected mechatronic unit ) i faced here in my workshp.
Had an issue with the DSG gearbox in my 2010 MkV1 GTI since purchase in the USA. Constantly jerky to motion from stop and significant lag between accelerator pressure and vehicle movement.
VW engineers refused to believe me until they took a ride and couldn’t understand the issue. Had the car in the shop about 6 times from 2k miles to 15k miles and they still can’t work it out.
I’m having the mechatronics unit replaced FOR THE SECOND TIME in only 15k miles!! VW GTI does not define quality engineering. VW should start sourcing a new gearbox as this model is clearly consistently faulty. I would NOT have purchased the GTI had I known about this and WOULD NOT purchase another….ever!
I am from Trinidad and i have a Jetta 1.4 tsi, 9 months old. on Friday the car’s gearbox just did not engage, no problems before that. I’m waiting for my new mechatronics module from Germany too,they said three weeks to get it. also think VW needs to look into this.
Hi David, I have a 1.4 tsi too, 11 months. I noticed rough engagement of second gear recently. What issue did you have? The dealer made some adjustment at 10,000 miles but offered no explanation.
Just had the Mechatronics unit replaced on my 2008 R36 Passat CC with only 17k miles. The main issue was the 0 to motion delay and “Jerky pickup” in both fwd and reverse alond with a crashing sound which felt like the car had been shunted, when pulling away. I’ve had the car for 18 months (ex demo) and believe that it has been evident from day one – albeit intermittently!
The VW dealership was very responsive once I reported the issue (almost as if this wasn’t the first time they’d heard of the problem…). Picked the car up today and the problem is sorted, feels like a new car.
Main vehicle warranty is coming up for expiry soon and I’ll really have consider extending it or selling as based on the other posts here it looks like this could be a recurring problem!
Anyone know what warranty VW give on the new part?
Hi all,
Mine Golf Gt 140Pk bj 8/2008, had also a problem when I stopt for a traffic light, the gears 3, 2 and 1 where shifting back with a great shock, I couldn’t found a fault with my Vag-Com cable but in the repair station (vw) they said we can go deeper in your computer, and yes they found a problem: they had to replace the Megatronica, 2 days work.
And after that I went to the DSG Dokter in Aalten The Netherlands and he reprogrammed the hole gearbox and also for the engine, now +/- 180Hp and 378,8 Nm Torq
And in S it shifts over by 2500rpm, and till about 70% gaspedal, it stays in 6 because there is power enough, and over 70% it shifts back, but I never use that.
And what is very nice, when you are accelerating, then after 1 meter of so, it shifts to the second gear, and it stays there until you stops.
And if you want something else, he can change it for you, it’s what you want. Price almost 1000 euro for motor & Gearbox.
Even the Vw Dealers from Holland are visiting him, if there is a problem which they couldn’t fix.
He can also upgrade your gearbox: stage 1 to 5 or higher. (for turbo engines)
And if you want he can put back the standard settings. (for warranty factory)
For questions you can call him:
For the Netherlands, (00 31)543-478914
TVS Engineering
Nijverheidsweg 26
7122 AB Aalten
Tel. (0)543-478914*
Fax (0)543-479436
Gr Mike
Hi Tony,
The warranty is standard 2 year, but after 2 years here in The Netherlands you get 2 weeks or so, to decide if you want a year extra warranty with a maximum of 6 years or 160000km or so.
And your gearbox is within this warranty, my first Golf 140Pk Dsg was ok, but after a year or so, I had a problem with the 2 mass flywheel ( also a big problem within the Vw Group) but it was also a warranty item
Gr Mike
I have a 2008 Wolfsburg Edition Jetta. I complained several times over the last 30 months about the same 0 to motion delays and “jerky pickup” in both forward and reverse. The dealership made me feel like a fool, saying that they could not find (duplicate) the problem, so “nothing is wrong”. Then about two months ago, I received notification from VW (letters) that there was a problem with he mechatronic control unit in our model, and that it would be replace dfor free, and the warranty extended to 10 years. I felt vindicated. I just had the new unit installed today, and the car (like Tony’s above) feels like a new car. [I had a similar service issue with a Mustang GT - they couldn't duplicate a problem that many were blogging about.] When are the service departments going to take our concerns seriously the FIRST TIME?
My 2008 GTI would lose power off of the line and result in a “check engine” light. The warning light would resolve after removing the key.
After recieving a letter indicating a recall notice on the mechtronic unit, I scheduled an evaluation appoinment. Fortunatly, my dealer ran a full diagnostic. Apparently it is common for the fuel pump to fail and cause damage to the cams and followers…
My dealer replaced the mechronic unit, cams, followers, and oil change with no charge!
My 2007 passat dsg has grinding noise coming from left side garage says gearbox gone it will cost 3500 pounds to replace..will have to scrap car what a problem
My brand new Tiguan DSG (5 months old with 5k on the clock nearly killed us all today, lurching from D3 to D1 in a blink of an eye. Limp home mode only (D1 and no reverse). dealer says faulty mechatronic unit. New unit ordered…2 weeks wait for part. Not impressed.
My VW GOlf bought new Dec 2009 which has only done 26000km has a dead machatronics unit… 2 weeks wait for part, no VW supplied replacement car… absolutely disgusting! In process of contacting major VW managers in Australia to actually get a copy of my new car warranty (they say the paper form doesnt exist). Not going to put up with this, will be selling my VW and bagging the company for the rest of my days!
Our Golf 2009 TSI stopped moving today.
The engine light is on, and when you place it in D (or any gear), nothing happen. We tried turning it on and off, but nothing. The engine starts and revs ok – just no movement.
We had the clutch replaced after 12 months, and the engine replaced at 18months old.
VW Australia better get this car in order.
This sounds exactly like what happened to me today. I have a Golf GTI (dsg). Was driving and the car suddenly popped out of gear. The engine was still reving and running. Would not go into drive, reverse, nothing. At mechanics now? After reading this blog, I am now worried $$$…what did you guys do?
I have a 2008 GTI and was experiencing the jerkiness. Called VW, they told me about the recall. Got them to replace the mechatronics unit and now it feels like a new car. Did they actually extend the warranty on these cars as a result of this problem?
Also, what is VW saying about the re-engineered unit? Do they feel that they’ve fixed it?
My 2010 VW Golf 1.6 TDI DSG’s mechatronic control unit also died about 4 weeks ago, and the part has to be made in Germany. Had to use the horrible public transport for a week while VW did not have a courtesy car for me. I have been driving a Polo Vivo ever since (manual) and feel inconvenienced by having to pay installments on a car I do not have. Why does VW not have these ready made, and only coding done for the sepcific car once it has broken down?
@Kevin: Wow, so if your Tiguan is a 2010/2011 model then that means VW has not solved the DSG transmission problems yet. I will be avoiding the DSG and sticking to the manual trans when/if I get the Golf as my next car. What a shame, and they want to be the top automaker by 2018?!? Maybe they will figure out the DSG problems by then, or else they will achieve their goal only to have the same issues that Toyota is facing now.
I have a Golf GT TDI 2.O 140 I put it in reverse and it went forward instead. Took it to VW and they cant reproduce the fault so wont help. Having real trouble with them. Car is jerky and the dsg gearbox is sluggish. They tried blaming a gear box oil change and I proved it was done by VW. They have now gone back to blaming lack of reproduction of fault even though the computer is showing it occurred. Can anyone help with suggestions on what to do?
My 2006 A3 2.0FSi Tiptronic although not a DSG has apparently packed up on the gearbox @160000km. Mechanic says it’s the Mechatronics.And I thought I would drive this car for a while. And knowing the dealers in SA I will pay a fortune to have it fixed.
My 2009 jetta wolfsburg has a bad mechatronic unit for the second time now, first experienced the jerk from complete stop to motion and now the vehicle shifts into neutral without warning which considering I drive highway most of the time very dangerous. Many other problems with the car, first and last VW I will ever own.
2007 GTI with 122,000 miles. The Mechatronic unit is out and the car is in the shop now. Failure on Tuesday and c the car is expected back on Friday – mild compared to stories I’ve read here. My concern is safety in that the way my problem occurred was a sudden down shift to 1st gear with out warning. Fortunately I was in city traffic and was able to handle it. It could have been very different at highway speeds. The only symptom was: 1) a slight “shuddering” during acceleration. I thought this was fuel related and spent some money on fuel injector maintenance. Very rare, it would only happen once a week on a car driven daily. 2) The “PRNDS” display on the instrument panel on occasion would cycle repeatedly (a “cycle” being; characters lighted, background dark to characters dark, background lighted). The Transmission worked fine during the cycling and you could reset it by turning the car off and restarting it.
My 5000 mile Nov 2010 Tiguan 7 speed DSG failed me. Mechatronic unit at fault apparently and they say that’s very unusual!?! Waited 2.5wks already and parts not yet shipped to VAG Milton Keynes, let alone arriving locally and job getting done. At least as motability customer I’m still on the road. Very worried about above list of failures. Definitely changing my mind about keeping it in the family afterwards.
Just found out my 2500 mile GTI (bought brand new on April 2011 ) needs mechatronic replacement. I felt similar lagged response and burst pick-up as others as well as stalling sensation at low speed. I told the dealer about the issues when I brought in the car for 3 month check up. They originally said no issue found (no computer error code recorded). I insisted on having a test drive with them, and the technician found the problem during the test drive.
Now I am waiting for the part to arrive.
As Steve an Kevin, I had the same problem with my brand new CC (May 2011), with only 1200 Km!! The DSG6 shifted from D5 to D1 in just 1 second @90Kmph!!!! I was lucky to drive on countryside road with no traffic… otherwise I don’t want to think what could happen…
Mechanics sad that they don’t know yet the problem and waiting instructions from the producer…
I cannot believe that is happening with a car not older than 1 month!
Now 4 weeks without my car!! They have fitted the parts last week but cannot re-program the mechatronic unit?!
I have a 2010 cc with 13,000 miles on it this “megatronic” unit went bad car shifted irraticaly, brought it to the dealer they told me it was safe to drive till part came in. $ days later i was at the car wash and the car wouldnt go into Reverse or into drive. Had to have car towed to dealer. Then unit came in last week but they shipped wrong unit from Germany?!?! Not happy with vw any other reviews about this unit and how/why it fails?!
LEARN FROM MY MISTAKE. When they start telling you it is the mechatronic unit — sell the car as fast as you can. My 2008 is about to get its 5th mechatronic unit replacement; also had two transmission replacements. Each and everytime I thought this is it, now my car will work properly. The Dealer will continually tell you there is no issue found (no computer error code). They will tell you that they cannot replace parts without authorization from VW. They will smile at you and pass the buck. They will tell you they are doing everything they can.
I had no real issues with the 7 speed DSG in my 2009 Golf 6 1.4 TSi until one day at 44,000 kms, the car would not engage any gear. Had it towed to the dealership and now waiting for the mechatronic unit to arrive. The dealer knew what it was straight away which makes me think this happens all the time. Luckily still had 6 months to go on the warranty period but given the feedback here, I will be selling the car as soon as possible to ensure I’m not forking out big dollars once it goes again and I’m out of warranty.
It’s such a shame about the reliability issues with VW as they are good cars but so expensive to maintain once the warranty lapses. I had similar reliability issues with my old Golf4. No problems with the 6 speed DSG in my wife’s TT though so I guess you get what you pay for if you’ve got the ca$h for an Audi.
Hey guys – brought a golf mk5 gti dsg 3 weeks ago from a volkswagen dealer in London, recently got it diagnosed at my own dealership as it was jolty from 1st to 2nd and reverse. They concluded nothing was wrong and it was normal, a week later i forced the services manganger to drive it and he said it may be the mechatronic unit, so they ran tests and VW concluded it defintately needed a new one. Now the dealership called earlier to say ‘we need to get confirmation this is covered in warranty by head office so we will call you tomorrow’. Is there any chance they will say it isnt covered? If so what can i do?
Hi,
I just took my DSG TDI Jetta back to my VW dealer after noticed jerky actions when changing between 2-3 a 3-2. They advised the mechatroics unit is faulty and is also a common and well known fault just lucky i am under warranty still.
I have been since told that the Gearbox and fly wheel are to be replaced to and they are still not sure if this will resolve the problem. Seems to me the DSG is a great idea but F*ing expensive if your warranty runs out.
Follow up comment after the mechatronic unit on my Golf was replaced by VW in September after it all went wrong in August. They also replaced the clutch as apparently this was also faulty. The car ran well after the replacement for 6 weeks but it happenned AGAIN before I had time to sell the car. The car wouldn’t go into any gear, just revving like it was in neutral. Had it towed to the dealer again yesterday so will see what excuses they come up with. Moral of the story, sell car now before warranty goes in 5 months!
Please anybody know any problems in DSG gearbox of new Golf-6 7-speed DSG 1600 cc 102 hp FSI (petrol fuel) model 2011 as i am going to buy new GOlf-6 7-speed DSG 1600cc 102hp FSI next month. Please advcie if i can goahead and buy it or stop this idea?
Regards
Ahmed Said
i have a golf 2.0 tdi dsg 2004.Now it has a fault that does not show on diagnostics or on dash
runs ok until i put my foot down and i lose power,and the only way to regain my power is to switch off engine and start it up again,then power returns only until i put my foot down again.Could this be DPF OR MECHARONICES anyone?
i have a golf 2.0 tdi dsg 2004.Now it has a fault that does not show on diagnostics or on dash
runs ok until i put my foot down and i lose power,and the only way to regain my power is to switch off engine and start it up again,then power returns only until i put my foot down again.Could this be DPF OR MECHATRONICS anyone?
Whilst on the freeway my clutch pedal,on my 2009 Gti 6 purchased brand new, failed. Quick think i managed to pull it with my foot so as to steer to safety. Car was towed to the dealership and got a call this morning to advise the clutch is burnt. Outrageous! !!!!! It only doing 50k mileage. And its a top end Gti for crying out loud. left my buddy in a state of shock as he watched my car being towed. Crazy. Ordered the R, wonder if it can handle the pace.
i m from tunisia
my 2009 vw golf 1.4 tsi had a mechatronic failure and they told me it coasts 7000 dt.
now im waiting for the new part for like 3 months and no reply from the dealer.
Hi Jojo, I do have some advice for you. Call 98 335 271.
hi Jojo >>i have the same problem
i’m from egypt >>my golf 1.6 had a mechatronic failure 6 months ago..i brought a new one,
it worked well for about 5 months and now i have the same problem (mechatronic failure)>>i dont know what to do
I have a 2010 Golf 1.4 TSI with the 7-speed DSG box. I took the car in for its second service just before Christmas, with the mileage at 37000. When I dropped the car off I mentioned that the engine sounded rattly on start-up and the gearbox wasn’t behaving normally.
The engine needed new cam sprockets & tensioner, and the gearbox needed a new clutch. Having done all that, they said the gearbox still wasn’t working properly, and they had sent the data back to the factory. The response was that it needed a new mechatronic unit, and that these are effectively built to order.
So, to date, I’m still waiting to get the car back. Fortunately the dealer has provided a courtesy car. This has really shaken my faith in VW engineering.