Volkswagen DSG – 6 Speed Mechatronic Control Unit

dsg_trans_mechatronics_1

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.

Conti Temic microelectronic GmbH, headquartered in Nuremberg, Germany – an international supplier of electronic chassis components for the automotive industry – employs Ultradur® B4300, a BASF polybutylene terephthalate (PBT), in the manufacture of the integrated control unit for its new double-clutch transmission. The transmission control unit is a sophisticated, compact mechatronic component installed directly on the gearbox, meaning that it is immersed in hot trans-mission oil. Two variants of this BASF plastic offer the requisite high-temperature and chemical resistance. This innovative automatic transmission – serially produced at VW for the first time in 2003 – has now found its way into the Golf, Touran, Passat, Jetta and the new Eos models.

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.

dsg_trans_mechatronics_2Such 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.

86 comments to Volkswagen DSG – 6 Speed Mechatronic Control Unit

  • Kelvin

    Driving a brand new mk 6 jetta 1.4 tsi sports 160 hp. No jerkiness experienced with the 7 speed dsg. However car came with minor faults.
    1. Rear seat belt stuck.
    2. Front passenger door needs more force to shut compared with the rest.
    3. Both rear doors panels deformed, does not sit snugly .
    Given the run around at Vw Singapore, now they need another 2 weeks to order parts…..
    New car and it has been in the shop twice.
    Should had stuck to a jap model….my 2 previous jap cars ran flawlessly . So much for German engineering…or should I say Mexican engineering.

  • AHH

    2012 GTI,6 DSG,made 2011-11-29, China, brandnew 300km, transmission failure, awaiting shippment from germany………….

  • Charlie

    I was driving my 2007 Passat on the high way crusing at 70mph… my trans slipped, downshifted on its own and the engine redlined followed by an uncommanded shut down. My 2007 Passat is now showing PRNDS with a knocking engine. The car seems to be in Neutral but nothing will happens when shifting from Park. Looking at the blogs, I have a busted trans and a busted engine because of the trans. I have 111,000 miles on this car and not a scratch (Wolfburg). I will not get another VW after this expierence. The myth of getting 200k out of a VW is far fetched. Looks like I will be out car shopping soon and carrying a car note for 1 more year on a POS that I drive.

  • JOHAN

    I have a 2007 A3 20t fsi Audi DSG bought s/h and got a serging problem going forward from 0km and even worse in reverse ,I have had vehicle at agents under m/plan they replaced h/pressure fuel followers and now its back for vacuum issues all to sort out jerking and hard shifts.I asked them about the Mechatronics unit but they are ignoring me on this question.Unfortunately for them I had a Jetta FSI t before and was the nicest vehicle with its DSG to drive no problems.I will take this Audi back untill they fix it and my m/plan is coming to a end in June (sorry it is there issue).I am in South Africa and maybe they dont want to lay out the money for this unit for I hear it is expensive.

  • Waleed Al Sahhaf

    I just got the new 2012 VW GTI. Drivin in it 10663KM so far iv only had for about three or four months. I was speeding on the high way quickly switching from lane to lane and as soon as i threw it in sport (S) to get some extra speed so i could get through some tight spots all of the sudden the car just pulls back and shuts down, spedometer was down to 0km and the rpm was over reving, it froze the car was usless for about 30sec to a minute just flat out stalled!!! i could have been killed!!! “The Mechatronic is damaged and needs reprogramming only” according to the delearship techs and head office here in kuwait. They even told me that i may need to come in every once and a while to reprogramme the mechatronic and that its normal and i shouldnt worry they say. After reading all these blogs i am very worried about the safety and reliability of my GOLF GTI. This is a hazard risk to me and people around me regardless of how i drive or where i am on the road you dont need to be speeding at all in order to cause an accident when your car just decides to shut down and stall in the middle of the road without warning… Thats enough!…. what if i keep fixing, reprogramming, and replacing the mechatronic till my warranty ends then what ? they will eventually stop covering my damaged car ? then what ? What a mess!

  • Joseph

    I have a 2007 Golf Gt 1.4 TSI DSG car & i have a mechatronics problem with it.. I need to change my mechatronics.. Does anyone can suggest me a place to buy it & can you give me an idea about the price of it please..!!??

  • I wonder what VW is doing to solve this problem. Just asked my service provider how much it will cost to repair the megatronic controll and they say 11000 South African Rands! Expensive if you ask me!

  • John

    Mine just died in my 2012 CC.

  • Paul

    Picked up a brand new Tiguan 103 TDi with 7 speed DSG and right from the first trip we had problems. We could not select reverse gear, the car stuck in first gear twice and the catalytic converter warning light is on most of the time. The dealership advises that it is a mechatronics problem. So far that’s the level of detail I have, but to their credit I have a new Jetta DSG diesel to cruise around in until they fix the problem.

    The inbuilt SAT NAV is also a problem as the loaded maps don’t seem to have any of the addresses we’ve tried to find using the system. Not a good start with my new car.

  • Tom

    My 2007 VW GTI with DSG and 71K minles, went out of gear with all four gear indicators blinking. Once I pulled to the side of the road, the car would not move, regardles of whether or not the engine was running. The dealership stated that “we just needed to reporgram the computer”. When I got it back, there was a pronounced clunk when transmission downshifted from 2nd to 1st at low speeds. Back to the dealership where they claimed it needed new clutches ($2000). Clutches replaced, problem not solved. Now they’ve decided the mechatonics needs to be replace (for free thankfully). I suspect that should have been the solution for the original problem if they had road tested correctly. I really like the GTI, but with this kind of inept and expensive service, I can’t wait to trade it in for something simpler, cheaper and more reliable (maybe a horse).

  • Paul

    Trust me a horse is more expensive, someone in my family has one and stable/feed costs a fortune!

    Heard from the dealer today and the new mecatronics unit arrived this afternoon and I may have the car back early next week. I sincerely hope it works.

  • Joshua

    Should put all the comments on the Volkswagen Facebook site for all VW owners to share.

  • James Snyder

    I have a 2006 Jetta GLI (2.0 FSI) with DSG. I reported intermittant failure to downshift at 20K mi to dealer and a heat related erratic downshift/loss of power several years later. Recently while in high temp environment DSG would not engage reverse or forward for some time and then would violently engage. I can’t get a straight answer as to what cars are covered but was told Audi is giving 10 year, 100K extended on DSG.
    What are my chances with VW of A???? Phone number???

  • James Snyder

    I have a 2006 Jetta GLI (2.0 FSI) with DSG. I reported intermittant failure to downshift at 20K mi to dealer and a heat related erratic downshift/loss of power several years later. Recently while in high temp environment DSG would not engage reverse or forward for some time and then would violently engage. I can’t get a straight answer as to what cars are covered but was told Audi is giving 10 year, 100K extended on DSG.
    What are my chances with VW of A???? Phone number???

  • Jai

    I have a 2009 Golf TDI im young driver 90% of my driving is urban all my services was done with the same dealership so i started experience problem making noise when coming to stop at slow speed when gear drops from 4 to 2 in between stall’s at complete stop when taking off 3rd gear RPM rises to 3.5 befor it changed to 4 where 1’2’4′ changes at 2.5 RPM it’s so annoying i was so disappointed i stop listening to radio i became furious whats causing i was so sad, i showed it to them they did road test and on computer they said they couldn’t find any error code in the past 8 months its been in for fault check up 3 time’s also at every service interval it gotten worst i made note that i am still experiencing the same problem when it went in for service, well i had some mechanical background worked on car’s with my father i knew it was the gearbox so they said it was CV shaft it got replaced 3 day’s latter it started making the sound so the CV shaft leaked grease got damaged went for another road test they finally accepted it’s the gearbox the mechatronic need’s replacing it was so difficult convincing them i was having nightmares, VW Australia has problem with they workshop’s not qualified to do the jobs in these europcar’s.

  • Alan Lafferty

    Just been told that my 2006 Passat dsg is stuck in two gears, and will either need a new Mechatronic Control unit & hydraulic selector, or a whole new gearbox at £4k!! not very impressed.

  • Gopal

    I am driving a 2009 VW Golf 1.4 TSI and recently the mechatronics broke down. It cost me almost S$9000 to get it replaced. VW cars are certainly not reliable.

  • 2012 passat, just drive it 3887 km and the transmission stuck at D2, send in to VW for repair and need to change the mechatronics…

  • Amiya

    Please Let me Know if Gear Box damaged is it mandatory to replace the Clucth

  • Jeanette

    I have a 2009 VW Caddy Maxi Life it was surging and getting stuck in gear after 50klms or so driving I only bought it from dealer for 2 days, tried to get VW to replace the Mechatronics unit as it was just out of new car warranty but they wouldn’t so car dealer had to pay all. I just hope this one will be ok as it cost $5,086 Perth, Australia

  • fadi

    I have gti 2007 2.0t i want to replace my old mechatronic where can.i get one in usa

  • XX

    18/04/ 2013 I bought a second hand 2007 VW Passat 36000 miles, full service history from new here in the UK from a used car dealer, it been jerking in slow moving traffic, really hard to control and keep her stead very uncomfortable. I have taken it back to the private dealer after reading about the DSG Problem who in turn took it to a Volkswagen dealer. We said to the dealer that we are aware that there are call-backs for the DSG problem in other countries, what about here in the UK. He denied any knowledge of DSG problems. So I have left the vehicle with VW for diagnostic test which is costing £68.The Mechanic said “it needs a software update”, who is he trying to kid. On the way out of the VW dealer service centre I met an old friend of mine who is an engineer for VW, he told me a few things about the problems of DSG gearbox he told me they are F*@ked up basicaly.

  • Jim MacBrayne

    I have a VW Golf R32 which was bought new, is four years old and has done 56,00 miles. While it was still in warranty, about two years ago, a sensor had to be replaced, which involved having the gearbox removed, but at no cost to me. This week it wouldn’t go into any gear other than 1st or 2nd and I took it to the dealer. Apparently it needs a new mechatronic unit plus a few other bits and pieces – total cost £2,600 GB including labour. It’s only now, when I read sites like this, that I realise maybe these gearboxes aren’t quite as reliable as I had thought they were! Makes me think I’d be better going back to manual, though I do love my paddle change!

  • DSG is bad

    I havbe a MY2008 Passat. It has a failed Mechatronics unit in its 6 speed transmission. It has done 83,000Km. Do not buy a VW! I will be repairing and selling my lemon as soon as I can. I recommend that you avoid my mistake. VW does not care about their existing owners, they just want new owners.

    • Tired of VW quality

      I have 2007 Passat 2.0TDI with a knackered transmission. I felt something break in the drivetrain while driving about 50kmh. After which reverse not selectable and in drive can only inch along with horrible noises. Done 140,000 less than trouble free kilometers so far and was hoping to be able to do much more. Cost to repair – US$7k!!! So I am not sure that will be happening. I am gutted and disgusted with the constant mechanical failures this car has suffered (busted oil pump, busted fuel pump and last year had to have new engine fitted!) Now this….Can’t say I am as thrilled with VW as I was when I first picked up my particular piece of citrus.

  • Brent

    I purchased a 012 in November 2012 and after several months, we noticed the car would intermittantly shudder at 5-10 km hr (parking lot speed) at light acceleration. At 15,000 service, I mentioned this to the dealership and was told it was normal for the dsg transmission. Trusting in the dealership, I was satisfied. Jump forward to 32,000 km, the low shudder continues and is now doing the same at consistanty between 55- 60 km/hr.

    A quick drive with the mechanic and he asks to have it overnight for a cold start and drive. The dealership now tells me it is the mechatronics and the part is ordered. It appears this is more common than I thoughts d would assume the selling dealer would be aware. Still under warranty for another 2 years. Time will tell

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  • Gavin Morado

    2010 Passat has a mechatronic failure problem. It took a while for the dealership maintenance to figure it out. I am seventyish in age and I fear that while in motion a lock down will happen and the Passat will flip over. I wonder if the replacement will be adequate and safe while I drive this lemon. If anyone else has had this problem, please bring it up, maybe Volkswagen to give us a replacement vehicle.

  • Christine

    Just bought a used EOS at the dealer with 54k on it . Fortunately it was still under its limited used car warrantee and bought from the dealer as right after purchase it developed a shudder/ lurch shifting from stop to first and first to stop. Took it back in, needed mechatronics unit. Boy I glad it was under warrantee!! I got the impression from the mechanic it was not an unusual problem…. Which isn’t a good thing for VW…

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