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DSG and S tronic gearbox repair
VW Group’s dual-clutch boxes are strong units with a small number of very well-known failure points. Almost all of them are repairable, and most of them cost less to repair than people expect.
12 month warranty
Work out which box you’ve got first
The failures are completely different. Dry-clutch boxes fail at the mechatronic unit and the clutch. Wet-clutch boxes fail at the clutch packs, the solenoids and the sump filter.
The DQ200 is the one we see most and the one that causes the most alarm, because when the mechatronic accumulator fails you lose drive completely, without warning, sometimes at a junction. It’s a known fault, it has been a known fault for well over a decade, and it is entirely rebuildable.
A mechatronic unit that isn’t correctly adapted to the car will feel wrong even when the mechanical work is perfect. Where the car is with us it is coded, adapted and road tested before it leaves.
A unit sent in on its own cannot be adapted off the car. It comes back cloned and coded as far as the unit allows, and we supply the adaptation procedure for whoever fits it.
Gearbox families
| Family | Code | Type | Torque | Common applications |
|---|---|---|---|---|
| DQ200 | 0AM / 0CG | 7-speed, dry clutch, transverse | approx. 250 Nm | Golf Mk6 and Mk7, Polo, Fabia, Octavia, Leon, Audi A1 and A3, Ibiza |
| DQ250 | 02E | 6-speed, wet clutch, transverse | approx. 350 Nm | Golf GTI and R Mk5 to Mk7, Passat, Tiguan, Superb, Audi A3, TT |
| DQ381 | 0GC | 7-speed, wet clutch, transverse | approx. 420 Nm | Golf Mk7.5 and Mk8, Tiguan, Kodiaq, Superb |
| DQ380 | 0DE | 7-speed, wet clutch, transverse | approx. 380 Nm | Golf Mk7.5, Passat, Arteon |
| DQ500 | 0BH / 0BT | 7-speed, wet clutch, transverse | approx. 600 Nm | Transporter T5 and T6, Audi RS3 8V, TT RS, Golf R |
| DL501 | 0B5 | 7-speed S tronic, longitudinal | approx. 550 Nm | Audi A4, A5, A6, A7, Q5, SQ5 |
| DL382 | 0CK / 0CL | 7-speed S tronic, longitudinal | approx. 400 Nm | Audi A4 and A5 B9, Q5 |
| DQ400e | 0DD | 6-speed hybrid DSG | — | Golf GTE, Passat GTE, Audi A3 e-tron |
Scroll the table sideways to see every column.
Torque figures vary by application. Mechatronic part numbers vary by model year and software level. Send us the number stamped on your unit and we’ll confirm it.
Common faults
| Symptom | Likely cause | Codes commonly seen | Our fix |
|---|---|---|---|
| Sudden total loss of drive, gear display flashing | DQ200 mechatronic hydraulic accumulator failure | P17BFP189C | Mechatronic rebuilt with an upgraded accumulator, bench tested and coded; adapted once it is back in the car |
| Judder pulling away from a standstill | Dry clutch wear or glazing; wet clutch pack wear | P0841P0842 | Clutch pack renewed, adaptation reset |
| Harsh or jerky low-speed shifts | Solenoid wear, contaminated fluid, blocked sump filter | P0868 | Fluid and filter service, valve body assessed, solenoids replaced |
| Won’t select reverse, or limp home in third | Clutch actuator or fork wear | — | Actuator and fork renewed |
| Gearbox overheat warning | Wet clutch pack wear generating heat, degraded fluid | — | Clutch pack, fluid and temperature sensor |
| Random gear selection warning with no mechanical fault | Mechatronic temperature sensor failure, common on DQ200 | — | Sensor replaced within mechatronic rebuild |
| Whine from the box on the move | Bearing or differential wear | — | Full strip, bearings and differential assessed |
Scroll the table sideways to see every column.
code a stored fault code. software a calibration or coding action. — no code typically logged.
What we do
Mechatronic rebuild, sent in or fitted. Clutch pack replacement. Full gearbox rebuild. Fluid and filter service. TCU cloning and coding. Adaptation reset and road test.
Send us the unit
You don’t need to bring the car. Remove the mechatronic unit, pack it, and we’ll collect. Everything comes back bench tested, cloned and coded as far as the unit allows, and warranted. Adaptation happens once it is back in the car, and we supply the procedure.
From £600 + VAT
For a DQ200 mechatronic rebuild, sent in on its own. We give you a firm price once it is stripped and assessed, and nothing happens without your say-so.
Frequently asked questions
Is my DSG worth repairing?
Almost always, yes. The mechanical side is usually sound.
How long does a mechatronic rebuild take?
Typically a few working days from receipt.
Do DSGs need a fluid service?
Wet-clutch boxes, yes, at the scheduled interval and arguably sooner. Dry-clutch DQ200 units have a sealed mechatronic fluid circuit.
Will you code it to my car?
If the car is with us, yes, and adaptation is part of the job rather than an extra. If you send the unit on its own we clone and code it as far as the unit allows, but nothing can be adapted off the car, so that happens when it goes back in and we supply the procedure.
Related
How it works
Sending us a unit
You don’t need to bring the car. Most of what we do arrives on a pallet.
- Drain it. Couriers won’t take a unit full of oil, and it’ll leak.
- Crate or pallet it. A gearbox needs to be strapped to a pallet or in a stout crate. A cardboard box won’t survive.
- Label it. Put your name, telephone number and the vehicle inside the packaging as well as on it. Labels come off in transit.
- Tell us it’s coming. Send the enquiry form first so we know what to expect and can book it in.
We can arrange collection anywhere in mainland UK. Ask when you enquire.
What happens next
- 01You send the enquiry.
- 02We come back the same working day with an initial view and, where we can, an indicative price.
- 03If it needs looking at, we book it in or arrange collection.
- 04We strip and assess, then ring you with a firm price before any work goes ahead.
- 05Rebuilt, tested, returned, warranted for 12 months.
No work happens without your say-so, and there are no surprises on the invoice.
Same working day
Send us the number and what it’s doing
The gearbox number, the vehicle and the symptoms. That is usually enough for a straight answer, and photographs are welcome.