Faults and repairs of 7-speed DSG gearboxes

What are all the problems and malfunctions that can occur with 7-speed DSG gearboxes not only in Volkswagen, Skoda, Audi, BMW etc.? Faults and repairs of different types of causes can be found here. Basic info about 7-speed DSG gearboxes.

1) Fault

Basic settings cannot be made or the gearbox is not working properly.

Damage to the K1 or K2 clutch caps.

When replacing the mechatronics, incorrect pressing of the release levers (use the prescribed workshop jig), incorrect mounting of the mechatronics or mounting of the dry clutches (damage to the piston pin caps of the K1 + K2 clutches may occur) and thus incorrect operation of the gear shift. Errors (P 175E - clutch K1) or (P 176F - clutch K2) may be stored in the diagnostic listing, indicating that the clutches are closing unintentionally.

2) gearbox malfunction

Control unit cannot be diagnosed, fuse SB2 or SB5 burnt out or burnt out again after its replacement, some control units may store error 01315 004 - control unit without signal.

Due to an undersized fuse, errors may be written in the control unit memory:

P177F - 21065 hydraulic pump motor voltage drop
P189C - 21247 cannot perform pressure rise diagnosis
P174A - 21108 valve 3 in gearbox section - electrical error
PO562 - 21148 electric motor supply voltage low
P175F - 21098 basic adjustment not performed

Possible error: incorrect installation of SB2 fuse in E box for power supply (15A fuse replaced with 30A) - fault in mechatronics (short circuit in hydraulic pump supply circuit)

Changes have been made since the mechatronics production date in 2011 (the date can be read in the control unit's measured value block 80). If replacing the fuse does not help, you must proceed to replacing the mechatronics.

3) fault

When driving slowly over uneven pavement (cobblestones, etc.), there are knocking sounds, jerking when starting, the engine switches off when more appliances are switched on, no transfer of power from the "R" position to the "D" position without pressing the brake pedal (the shift lever position light flashes).

Possible error - PO841 or 02113 - hydraulic pressure sensor 1 invalid signal // This record is only stored if the hydraulic pressure exceeds or falls below the prescribed value.

Troubleshoot only by updating the software in the mechatronics control unit.

ATTENTION : the battery charger must be connected to the battery during the entire software update!

4) defect

Noise, gearbox does what it wants, uncomfortable shifting or metal chips in the shape of hedgehogs are found on 4 magnets when changing mechatronics (gearboxes made before 2008).

Definite fault: Damage to the internal parts of the gearbox (bearings, wheels, etc.)

Repair or replacement of the gearbox, otherwise this 7-speed gearbox problem cannot be solved

5) defect

a) Vibration/ jerking when shifting from 1st to 2nd gear (multiple jerks, not just one jerk)

b) Vibration / jerk when accelerating into 2nd gear - the manifestation lasts approx. 2 seconds
- engine speed range 1 200 - 2 000 rpm
- at throttle boost approx. 20%
- when turning the vehicle - vibration, or when accelerating from a speed of 5 - 10 km/h (3 - 6 mph)
c) Vibration/jerking when starting to reverse speed

Cause: short-term uneven force transfer between the K2 clutch lining and the pressure plate, resulting in uneven torque transfer at different K2 clutch slip speeds

Remedy: Replace the double dry clutch according to the table above
- up to and including vehicle year 2011 diesel engine 0AM 198 140 B petrol engine 0AM 198 140 C
- from vehicle year 2012 " " " 0AM 198 140 " " 0AM 198 14

6) Different types of defects

Transmission without function, cannot change gears or sometimes the gear indicator is lost.

Vehicle jerks when in D

Vehicle does not start when in R

In fault memory (BNH): fault 19 143 004, P2711 - control unit without communication

Due to the high adhesion of the double-clutch, drifting of the blades can occur even after the double-clutch is disengaged.

7) defect

The vehicle will not start or shift after shifting is a fault in the clutches or pressure pump. G 107 pressure sensor fault (sporadic) may be stored - basic 1st clutch adjustment cannot be made.

Perform as per block - check clutches

if they are not OK, you must replace the clutches, but if they are I.O next procedure

do according to BNH No. 30 position 3 - check the actual pump pressure

After turning on the key and within approx. 15 seconds the pump pressure should be at least 42 Bar - gradually max 60 Bar, once 60 Bar is reached the pressure will start to drop again. If for a long time the pump pressure will be below 4 2Bar - troubleshoot - replace the mechatronics.

8) Fault - The speed lights are on and the vehicle is not moving

(double-leaf clutches made before 2009)

- An error is stored in the fault memory (BNH):

P072B/21073 - exceeded permitted attempt to shift R
P1899/21265 - clutch 2 limited function
P2789/10121 - P4 clutch 2 path too short

Troubleshooting - perform basic adjustment and adaptive run, if not corrected - replace double-blade clutch set.

9) Fault - speed lights flashing, vehicle not moving.

Errors are stored in the fault memory (BNH):

21062/21184 - P175 clutch 1 does not disengage
21063/21185 - P176E clutch 2 does not disengage
21094/21095 - P072C/D gear 1 and 2 cannot be shifted
21096/21097 - P073A/B gear 5 and 6 cannot be shifted

Due to impurities in the pressure control valves, the mechatronics must be replaced.

10) Fault - jerking, poor shifting or starting of the vehicle.

No fault stored in fault memory
the vehicle shifts late or early
jerky starts or slow gear changes

The cause is from an incorrect value of the longitudinal acceleration sensor!!!

Troubleshooting: check the engine for possible failures, engine performance and tuning, etc. and then perform a basic adjustment of the G251 longitudinal acceleration sensor in the brake unit.

11) Sometimes the power transmission fails, the vehicle does not run and the BNH stores fault P0604 or P0607 (internal mechatronics fault).

This is a mechatronics fault due to synthetic oil penetration into the mechatronics. This fault can occur even after you have changed the oil to mineral oil, which must be changed at 7°DSG. The oil change is from KT17/2013

Remedy for the fault: replacement of the mechatronics.

12) The vehicle does not run in reverse or at all.

Error P176D is stored in BNH (4-speed control cannot be shifted) and the key symbol or gear indicator flashes on the instrument panel.

This is a mechatronics fault due to synthetic oil seeping into the mechatronics. This fault can occur even after you have changed the oil to mineral oil, which must be changed at 7°DSG. The oil change is from KT17/2013.

Remedy for the fault: replacement of the mechatronics.