Transmission FAILURE ~ Damage From Driving With No Fluid
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- čas přidán 27. 08. 2022
- This DSG Transmission was victim of hitting something on the highway. All the DSG fluid leaked out. The car was driven until the DSG completely failed. The DSG was removed from a 3.2 Audi. We will teardown the DSG and inspect it, talk about DSG transmission problems. I did forget to make DSG Fart Sounds! #car #humblemechanic #dsg #youtube
How To Perform a MK7.5 DSG Service PROPERLY ~ • How To Perform a MK7.5...
How To Perform DSG Service for VW/Audi 6SP ~ • How To Perform DSG Ser...
DSG Transmission - Explained ~ • DSG Transmission - Exp...
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disclaimer:
The content of this video is available for informational and educational purposes only. It is not intended to be a substitute for the professional advice of a mechanic who has personally inspected your vehicle, nor does it create a relationship of any kind between the Humble Mechanic and you. Every situation may be different, and the Humble Mechanic does not make any warranties, whether express or implied, as to the accuracy, fitness, or applicability of the information or automotive parts portrayed in this video to any project and makes no guarantee of results. The Humble Mechanic and any sponsors of this video will not be liable for any damages related to personal injury, property damage or loss of any kind that may result from the use or reliance on this video and/or any automotive parts represented in this video. You are using the information and automotive parts portrayed in this video solely at your own risk. - Auta a dopravní prostředky
Really enjoy these kind of videos.. as a German car fan, and former transmission rebuilder, it's nice to keep a little up to date.
I remember back around 2008 when we started seeing DSGs with mileage on them and the dual-mass flywheels were failing. The springs would break and the ends would stick out between the two halves of the flywheel. They would grind on the bellhousing and damn near saw the transmission right off the engine! If memory serves, we saw this failure more often on TDI applications.
I had a manual TDI, and this same thing happened to me while on the highway. Felt something weird, didn't think anything of it - until a few miles down the road when the transmission was completely cooked.
Imagine the time and effort that was put in to designing these parts so you can shift gears like a pro… Love this content, I know there’s “ mechanics “ out there who fix cars on a regular basis but really haven’t got a clue how things actually work.
5k$ for new DSG?
Great and informative video! :) I still like my pretty simple MK2 much more than all this.
A new DSG can be as expensive as 15k$ on an Audi A4, but not this much here, probably half.
He never actually says what the price is in the video... However the part prices seem to be all over the place for what is the same 02E/DQ250 box. There are a ton of different variants based on exact part# and some "colour code". The part is apparently complete with the transfer case/diff, so the AWD ones are different but the price for a typical FWD seems to be $4-5k, whereas the AWD ones look like they are coming up as around $10k 😯 Not really sure if you can order the gearbox without the diff or takeoff for AWD. Used ones out of wrecked cars seem to be similarly a bit of a range--anywhere from $500 to $2k.
Love these kind of videos that are a little different, exploring how things work and what they look like on the inside. Keep finding stuff to take apart for us! And show us how to fix it when it might make sense to consider that.
Good video Charles. I used to work with a guy who was a former Audi engineer (he used to be in charge of the R8 transmission development). He was saying one day that even when a clutch pack is engaged (in gear) the transmission still slightly rides the clutch allowing around 1 RPM of difference between the input and output shafts. Hence why so many RPM sensors. In doing this the transmission knows exactly where the engagement point is and the exact torque that specific clutch is able to withstand. Awesome stuff!
What you've described is named "Mirco-Slip control", which is usually a counter measurement to the torsional vibrate to improve NVH/shifting performance.
The allowed continued speed difference in the clutch is usually somewhere above 10 rpm, and can be Much higher in a specified case (You can find one with ZF's DT8 in a Porsche model, branded as Virtual gear where more than 200 rpm is allowed. The dual clutches here have at least doubled plates, so they just stand the heat pressure very well).
The micro-slip control is also Widely used in the lockup clutch of the torque converter in an Automatic transmission, since the lockup clutch is substantially weaker compared to the clutches in a DSG.
The micro-slip control can be greatly/effectively eliminated if a centrifugal pendulum vibration absorber is applied along with the conventional dual-mass flywheel, the video shows an example from Audi A4(since MY2017):
czcams.com/video/YRxrajJCLr0/video.html
Saw the short, came back for the full video. Fun to watch 👍🏻👍🏻
The smelling of the clutch disks every time even though the smelliness had already been established was great. Made me smile every time :)
always love the videos charles thank you for all the insight an knowledge u have bestowed apon us like a great vw legend
Thank you for the insight to the DSG and making my mind up to buy manual if I can overhaul 12 speed truck boxes I’m man enough to go into a 6 speed but sorry I’ve turned in to a mouse when it comes to DSG squeak squeak great vid top lad 👍👨🏻🏭🇬🇧
Another really interesting video. I appreciate your doing these just for educational purposes. It's interesting to think that these will become a lost art once everything is electronic. It's kind of like a mechanical watch movement as against quartz. The latter is cheaper and more accurate, but what have we lost?
I love your vibes man, you remind me of a teacher I had in high school. I miss that man. He got me through it, lol.
Looking at your tools i think about when i started fiddling with my GTI at first i thought that the upgrade parts will bankrupt me, but the all the new tools broke the bank :D
I know VW always calls for brand new turbos regardless of what happens to them (wastegate problems and such). It'd be cool to see a rebuild and install of a turbo. I have like 3 broke K03's laying around and I'd like to rebuild them.
This is what we truly need ^ Thank you for mentioning it!
I’d love to see this too!
my shop has replaced dozens of turbos by just getting the worn one reconditioned. hasn't failed us yet and its far more cost efficient for the customer
@@bradleyburns255 I’ve wondered the same. I’m guessing it’s not cost effective to dealerships.
@@skippy5927 probably not. they'd want it to be brand new for less liability on someone else. also contracting to another company for the recondition may not be a good look for a dealer. whereas a private shop like the one I work for, it's nice to help another business.
Great video, DSG is my favorite "automatic" transmission.
Having rough shifts and almost stalling from a stop in my dsg, scared it’s going to take a shit on me and being able to afford a whole new transmission, great video👍🏼
Same here man! I have an mk5 08 GTI and feels like it’s about to stall when I let off the brake and jerks for a second or two when I engage the throttle. I’m thinking it’s my mechatronic unit and heard about vw sending out recalls for them during for those years. My local vw can’t find any history of it being done and they say that there aren’t any outstanding recalls for my vin. I’m not sure at this point if I sell the car or spend the $2.5k plus I’ve been quoted to get it fixed.
I don't know anything about that vehicle but it's nice to receive the knowledge.
Thanks for another awesome video, love learning more about these cars 🤓
Loved to see the teardown, thanks.
This was so cool to see how the internals work! Now, I sort of want a car with a DSG (mine is a 02Q manual).
I think you’re the only one who can help me out with my Gli
Hi Charl! I actually havent done DSG Clutches before. I have however opened and repaired Mecatronix before. Cool to know i've done at least one job you haven't. But apart from that. You showed me a ton of new things :)
@1:04 6,000 USD.
@17:11 I am sure you get a good one used from the scrapyard. It is mainly just the block, right?
@18:46 Yes, put a good one from a salvage car in. Those used run of the mill Volkswagens and Audis aren't exactly Bentleys, so they are easily totalled. 👍
Love the tear downs!
, wow, thank you very much for that video. Verry informative. I'm not a mechanic but now I understand certain things appen about my car, 👍👍👍
That oil maze is a work of art,
Wooop wooop I love it thanks for entertaining once again. I hope you are financially secure forever ♾
Its sad that we live in a time where there is so much environmental concern yet we build stuff like this were we just discard it. In a way the days of old were better for the environment as they were much more serviceable then now. And for those electric fans out there near end of life is going to be far worse for the environment just wait and see as it never gets better when you chose to dispose of something rather than reuse. As always love you stuff Charles 👊👊👊👊👊
Metal is recyclable 😊
thanks for tearing this down. Oh, saw you one day a few years ago outside of Leith. I wanted to say hey, but figured you are busy. Do you mind Hellos?
Thank you for explaining how dsg work
Great video Charles, Thank You👌👍😎
Very good information give you man .thanks
I've had to diag a mech unit once for a customer. Found a forum with resistance values for the actuators and was able to find the bad one. Ordered from rockauto for like $20 and the car is still driving and shifting today. Super surprised on how cheap it was!
That's why reviewers always tell us to avoid the dsg !!
No way. The DSG is incredible! You can’t blame the transmission for impact damage
@@HumbleMechanic oh is it? Then why they always say zf 8-speed is the best ever !! Not talking about impact but general reliability IMHO.
Always gotta give it the sniff test! I do that to every relay or contactor that burns up at work. Really fun when that happens to a traction motor!
Great video. I hope you do more tear down vids like this. One of my new favorite channels is “I Do Cars”, where Eric tears down failed engines. In fact he recently did a 1.8 TSI; I was yelling at the screen that he should have watched your video 😀.
He’s going to be gone for a few weeks; this would be great for you to fill the void. (Maybe when he comes back he gets an idea to tear down failed transmissions 😁)
Hahah how’s videos have crushed it. I haven’t had time to watch but love seeing him get views
Great stuff!! i would like to see more of 3.0tdi and or 2.5tdi
Teardowns are fun! Would be cool if you sourced some old bulletproof TDI like an ALH and showed us its insides
60 yr old lady, knows only a little more than avg about auto/engine/tranny mechanics in general... yet, here I am. I am of the thought that if you own a car, you should at least understand some basics of the beast, if you use a toilet, have a basic understanding of how plumbing works .. you get the picture. Great video, very well done!!
Awesome video, Charles! Mk5 door lock actuator issue just developed for me today. Hopefully I can just lube it up (giggity). Wish me luck! whole damn door skin coming off.
I vaguely recall doing something like that. Watch out as you might be Locking the car and find out the door can be opened. I ending up replacing the whole mechanism.
@@bradleycross5987 thanks for the heads up. I am doing the job from watching youtube and the Haynes manual. appreciate the heads up!
czcams.com/video/LuOJhZaGwnw/video.html
This latch is EASY! just keep your bolts organized, and be sure to preset the latch when going back totgether
NICE WORK SIR!
PRODIGY HumbleMechanic
Great video thank you very much
Take care and have a great
PRODIGY HumbleMechanic
From Nick Ayivor from London England UK 🇬🇧
Love it! Maybe a bevel box tear down?
Brilliant video, thanks man
I need to replace my mech unit. I'd love for you to do some content on that. Life your work.
I'm guessing $5999.98 for a new unit. Then a boat load more for shop time, which would make me sad 😢 because I'm to cheap to pay a shop when it gets to that price. Then I have to do the work, which makes me even sadder, because I don't want to do that type of work anymore. Thanks for the break down on this unit. It now makes more sense to me how it really works.
Excellent video! Now do one for a 01m. Still cars in the road using that transmision
O1E teardowns please! Brand new to your channel, and this was fascinating. Can you tear down an O1E or two? Why are they the best worst manual transmissions VAG made? Why are the FYF and GBE actually sleeper hits over the EDU, or even DQT? Why do those 1-2 shift collars fail so often? Why does the shifter feel like a soggy hot dog???
We actually rebuild some mechatronics on dealership level, at least on the east side of the "pond".
Instead of replacing the entire mechatronic, we just replace the electronics.
As for the price for a new one... about €7k including VAT and dealership mark-up.
nice job! well done. Wondering would you be able to put it back together to work again, or nah?
I like tearing down broken parts it's good learning experience. You may be able fix it. Or have space parts for another one
Finally got around to watching your beginner mechanic toolbox video. It'd be cool if you could make a series out of it. Maybe a 5k-10k budget for intermediate level building off the beginner
Thank you! I need to find someone with a 5k budget. So we can build a setup.
@@HumbleMechanic exactly, niche audience.
Watching your video explains why Porsche doesn't do any repairs on their PDK transmission, just a $20K swap (Gulp!) and you don't even get a core credit or a kiss before they you know what. That's about 15-20% of the cost of a base Carrera, crazy stuff. No wonder our dumps are full of cast-offs, I paid several hundred dollars to repair a big screen TV as it was in pristine shape, a capacitor had failed (cheap part), could have bought a new one for a few hundred more, just stubborn, TV still works years later. Thanks again, that's a little bit more of the mystery of a transmission revealed.
Ive fixed a few TV capacitors! $30 in parts, and its good to go.
Good work
Stuff like this is pretty informative. I've been wanting to juat grab a junkyard dsg and rebuild it with an lsd to swap over in my project gli but I'm still confused at stuff like shims, if you can actually replace the solenoids (it currently has hard upshifts with heavy acceleration) or if I get the correct trans code dsg or compatible one. It's a lot to process lol
There is a lot of NON-OEM voodoo out there. Im not expert enough to really be a good resource. Finding the info is so hard.
Really useful, here in the UK and Europe we have a lot of lower powered cars using the dry clutch 7sp dsg, think these have separate oil for mechatronic and gears with the clutch pack dry. My own car has this a 1.6tdi and tbf works great I love it, but I know if it does go wrong it’s basically a throw away part, do you have these in the US?
notification squad, Have a nice weekend!🔥🔥🔥
CHEERS!!!!
Love it, cheers !
I'm working in the heavy duty trucks and these types of trans mission are usually called an automated manuel transmission (or automated for short). I new in the feil but I know Eaton is a common brand for big trucks.
Hello there, I own a stunningly beautiful 2004 TT 3.2 DSG , and have owned it for 10 years now...it has 95000 mls on the clock and has a great service history too.
I noticed a slight juddering when it takes up drive from standstill around a year ago now ...but that apart it drives beautiful with plenty of power .
I just occasionally wonder if it is the start of something sinister and terminal?
Regards
Richard
The transmission case is an amazing piece of engineering! Charles, are the solenoids deeped in oil or in a dry case?
They are in oil too
Love the tear downs id love to see more of them. Also what are your thoughts on on the mk7 thrust washer issue causing "crank walk". i have seen some companies take the main caps and machine in a groove for a washer on each side of the cap. Do you think that may solve the issue?
I haven't seen the repair you mentioned. But it seems legit. Id love to see the bearing with the TW built in.
So it is an issue. It happens most on manual cars with upgraded clutch. It has happened on others but far less often. Im not sure this would stop me from doing any mods, or owning this car.
@@HumbleMechanic could you please look at my post. Someone has replied in your name. Though it was something you should look into. Best regards.
A friend just paid 4000 for a Pathfinder CVT so I'm going to guess 6000. Hopefully that includes the labor. Dealers and shops won't rebuild this but who does. Thanks for the update. Now I know why I stick to the manual.
Man nothing is cheap these days. LOL Stick around to the end to see why a shop wouldn't rebuild this. LOL
You should tear down a TF-60SN transmission. The Mini Cooper S uses that tranny and is prone to wear out its clutches' friction material, would be great to see its dissasembly process👍🏼
A new DSG is around $6k. That's what the dealer quoted me for my '16 Jetta hybrid when my mechatronics unit quit shifting into e-mode. I fixed it with a $0.50 o-ring.
Same thing happened to me on my 6MT….. but I noticed the gear lube smell and I patched it with JB Weld and bought a ECS Skid Plate….. so far it’s held up and it’s been a couple months……
I would be interested in seeing the 09A tiptronic from the mk4 disassembled. The solenoid pack is similar to the mechatronic unit in the DSG. I know a friend of mine has an 09A in his car and went through 3 of them before he found one that held up more than a year. No shift, stuck in gear, hard shifts, etc. Solenoid changes would fix one and then it would do the same thing after a while....or it wouldn't do anything.
Neither do I.
Like to see a video of the Tiptronic from Jatco.
Man, I wish someone could make a transmission like this with clear case, at least long enough to see the operation. I know it won't last but to just see it go through gears when spinning at speed on a bench top setup.... That would be cool.
The days of fixing things need not be gone. The more we accept that those days are behind us, the more we lose control of our own equipment and skills. Remember that if a human designed it, a human can fix it.
I burnt my k2 clutch using the HPA turbo kit on my 3.2 vr6 build. Bad install on my part, and maybe a lack of proper cooling, but the metal discs were warped so bad that they made a spring action and the gearbox would attempt to engage even in park.
I am curious though, what sensor takes the reading on the magnetic ring in the center of the input shaft? I noticed only the magnet on the shift fork is near it.
Hey, Charles! I love my 2012 TT Quattro 2.0T EA888.2 CETA. Paddle shifting is kinda cool-ish on the DSG. But, I was wondering if there's another option as my transmission starts to age. There are cutouts on the firewall for where the clutch is supposed to go. The Brake Master Cylinder even has a nipple off the side for a manual transmission. It looks almost plug-and-play, with the right parts. I am wondering if there is a manual transmission option that can be swapped? I miss my good old MKIV Wolfsburg Jetta with manual transmission.
My 2009 GTi DSG got replaced under warranty around 80k. I was told that the pump drive shaft was sheared in half. Symptoms were an odd delay when in reverse after it warmed up. Put it in reverse and it would either lurch into reverse or jerk into reverse.
I hate when there is one non-matching connector in a group.
As you said, there's probably a reason, it's just never a good enough reason. Lol
I have (possibly) a clogged valve body in my toyota with a standard automatic gearbox. Been wanting to try to clean out the valve body but found that the workshop manuals that I’ve managed to download online conveniently skip any mention of servicing the valve body. I wonder if this is a part that manufacturers tend to exclude from their manuals.
Отличный ролик!!!!!!!!!!!!!!!!!!
I will never have any use for this information but damn it sure was interesting to watch. I forget how far my friends over at United Motorsports tuning services reach. They’re just in a simple leased space in an industrial park, very small shop.
I have their ECM and Haldex tune on my r32!!!
Yeah crazy how when I did all of my research for my big turbo 1.8 build several arrows pointing towards these guys. Fred went above and beyond helping me out. 3071R with 870cc injectors, 2.0FSI crank, Schrick cams, bullet proof(resistant) valve train 🤣🤣and many many more dollars in parts coupled with his tune made it one bad ass ride!
oil change vídeo plis! tanks bro
351C+C4+9inch= years of fun 🍻
As for the price on a NEW DSG Box.. You are looking about $5,400 for the box, and at least another $1,000 for labor! Granted you get a new box, but you have to pay many Xs the price. Odds are that "NEW BOX" will exceed the value of the car. OCH!
For More DSG knowledge:
How To Perform a MK7.5 DSG Service PROPERLY ~ czcams.com/video/s0noV4JsSZU/video.html
How To Perform DSG Service for VW/Audi 6SP ~ czcams.com/video/AyfkGTfa9cU/video.html
DSG Transmission - Explained ~ czcams.com/video/mj1Vk7SE-TI/video.html
AWD System Failure ~ czcams.com/video/HfeGNsmG1zI/video.html
i guessed 5K for the box only. close enough
$800 for a used low mileage gear box shipped. Had to replace the one in my 2010 Wolfsburg Jetta. Couldn't find a used mechatronics unit I trusted, and new was $$$$
At least the dry clutch DQ200 7-speed DSG was around 4,5k€ + tax when mine ground the third gear into a pulp a year after warranty expired. Luckily Skoda covered the cost of parts and most of the labor due to low mileage (75k km at the time of failure) and good service history.
Brilliant video,thanks for sharing.
Was that a dq500 box with a wet clutch ?
Only asking incase it's the same as mine for future reference 👍
Like to see bevel box strip video if you get the chance too 😁👍
It is a DQ250.
The DQ500 just looks pretty similar, and it also shares the same concept of 3-piece synchronizer in gear 1~3 and 1-piece design in other gears.
It does a little trick in the reverse gear.
@@oijhhytdirhrbru thanks for the info on that, you sound like you know your way around these box's well 😁👍
That clutch is what we like to call clapped
I would like to see a teardown of a TR690 Subaru CVT next
What could be the potential issue or reason when you changing gears you feels like there is a gap between D-N-R in a DQ250 wet box? Wear out clutch packs or because of tuned DSG with higher clamping pressure caused this? TIA
Cars are so cool man
I would be very interested to see what's inside a tire. Would that be possible? I hear it is quite complex.
You are top thank you very Match
Had many of an argument about the starter side bolt.
As someone who dailies an Audi A3 Sportback e-tron with a DQ400e which is already on its 2nd mechatronics unit and 3rd trans fluid change, this is going to give me nightmares.
I for one would love to see a tear down of the VW 2.5L inline 5, or the Aisin 09g automatic.
The good thing about not seeing many Aisin 09g teardowns is it means they hold up well.
Typically, only valve bodies fail on them. They hold up otherwise. I have a 2006 Jetta 2.5 with 211K miles.
I'm surprised it was able to kill itself. I was expecting the clutch to release when there is no line pressure.
Even when these transmissions are working I hate the way they shift and take off. A good GM 4spd is much nicer.
In South Africa, it's cheaper to open and repair the Mecatronix and/or clutches than finding another box.
I would love more tear downs. Maybe a 09G? I don’t think you have any videos on that trans
I think this is a MUST! I would love to find a cheap MK5 with a bad value body and do some videos on ti.
2:59 - Wait, is Charles a gamer? Metal Gear is my favorite series!
I think I only played the PS1 version. LOL That said ive had plenty of Tony Hawk, and Mario Kart seat time
It's amazing how complex these transmissions are. One thing about the ID.4 is the trans only has one gear forward and one reverse. It's probably way more reliable just because of that. When these boxes are pulled out, are they sent to a rebuilder or anything like that? What happens to the old transmission when it's pulled and discarded like this one?
Does the ID4 need a reverse, most electric motors can spin in reverse?
@@harbl2479 good point! I’m not sure.
@@harbl2479 yes it needs a reverse and the starter motor is bigger and the clutch is much more expensive because of the high toruqe. JK there is none of that. the motor is always connected to the diff trough a reductor. Its always engaged and there are no shifts. the motor goes any direction and can turn at any speed.
The ID4 has no gearbox, it uses reducer and open differential only. A sporty battery-electric car may need a two speed transmission to increase maximum speed range, and we do have BEVs with a manual transmission, however it is not the case in most situations.
5-6k$ is what I would think the dealer would charge to replace it with a used dsg. ❤ mine, they're so nice if you take care of them
The previous owners Chinese axle blew up in my 2008 gti while driving at only 30mph and a piece flew into the DSG transmission blowing it up instantly too. It was ab 3k w a used dsg trans n new OEM axle LOL
Do the 2.5L 5 cyl. I wanna see how bad the rear main and whatnot are on these.
please car you do some research on the on the audi DL501/ PORSCHE MACAN transmission clutch having a ton of failures, why and the fix