Troubleshooting DSG Gearbox Problems and Repairs

The Vielles Roll Academy demonstrates how to fix oil sump leaks in a DSG gearbox, including replacing the mechatronics and the combined sensor.

### Repairing Oil Sump Leaks and Replacing Mechatronics in a Volkswagen DQ250 DSG Gearbox
* 🛠 The oil sump in a six-speed DSG gearbox like the DQ250 often **leaks and rusts**, causing problems.
* The solution involves an expert kit with a **new oil sump, seal, gearbox oil, and filter**.
* 🔍 Before starting the repair, a diagnostic test on the automatic gearbox should be performed to **check for errors**.
* 🔧 To replace the oil sump, the mechatronics must be removed, ensuring not to **damage the guiding bar and the rubber seal**.
* 🔌 When disconnecting the combined sensor connector, a screwdriver can be used to **separate the card**, and the new card must be carefully installed with **straight contacts**.
* After replacing the two seals on the plug going through the oil sump, the mechatronics can be **reinstalled**.
* 🌡 The combined sensor for oil temperature, clutch, and gearbox speed should also be replaced following the manufacturer's **tightening torque**.
* 🔍 It is recommended to check the electronic board for continuity using a multimeter and perform a **quick test of all control units** after completing the repair.

[Music] Hello from the Vielles Roll Academy in Oldenburg. We welcome you to today's video. We want to talk about three products that often cause problems in a six-speed DSG gearbox, like the DQ250 type. This gearbox is installed in many vehicles of the Volkswagen Group, for example, but also in many other vehicles. [Music] A common problem is clearly visible from the outside. It's an oil sump that leaks. On one hand, they leak here at the seal, and on the other hand, it's already heavily rusted. In many cases, they also rust through. We have a solution for you here. I have the solution you mentioned here. It's one of our expert kits that is suitable for this vehicle. This expert kit includes a new oil sump with a new seal, oil for gearbox oil change, a filter, so you have everything in order. Before starting the work, it's important to perform a small test on the automatic gearbox with a diagnostic tester available in stores to see if any errors are recorded. Currently, no problems are indicated on this gearbox. [Music] Here you can see how rust has made its way from the edge to the seal, and that's where it starts leaking. To properly remove the mechatronics, the oil pump cover must be removed.

Before the gearbox, there is a guiding bar on the mechatronics that should not be damaged when disassembling the mechatronics. You can see here the vulcanized rubber seal that should only be used once. Here is the black seal; you can see the sliding part of the mechatronics that should engage here; the tabs should not break during the process. The next step is to disconnect the cable or plug from the combined clutch sensor of the gearbox, oil temperature, and gearbox input speed. Pass it behind with a screwdriver, press the latch to remove it, then take it out of the receptacles here and set it aside. This prevents damaging the white case. To remove the mechatronics correctly, it is important not to loosen all the screws, but only those specified by the manufacturer. Please look at the image here and only loosen what is indicated. Before removing the mechatronics, I must ground myself like a mechanic; I always do this with my wrist because I have rubber gloves. During disassembly, you must ensure that the encoder arm of the mechatronics goes straight outwards. You can carefully lever it to loosen it; in fact, it's always quite fast.

Easy to do, then you must pull it straight. It is very important not to tilt it. The second particularity we want to address in this video is how to change this card to disconnect the connector. I place a screwdriver between the two, then I push here, and I can disconnect the connector, so the printed circuit board of the electronic unit is already disconnected. Then I will ask my colleague to help me because it is easier to work in pairs; one holds the card, and the other repairs it. When you place the new card, be careful and pay attention to the contacts. All contacts must be straight. Then you can press the card carefully. If the card snaps properly, you can start the final round. It is important that we also renew the two seals on the plug that goes through the oil sump. We have now replaced the two seals. We put back the electronic unit located above this card and reconnect the plug. We can now reinstall the complete mechatronics. Yoann, can you help me reinstall the mechatronics now? Wait a moment. When we have removed the mechatronics, we can show you how to replace the combined sensor for oil temperature, clutch, and gearbox speed. Why can't you take it out without the part inside? Because it

Look behind, take a quick look, that's where the pipe with clips is placed. It is set up here on the NFX side, and with a screw here, we have the sensor in question under the number B 10.72 1277. I will unpack it. Here is the right part with the connection cable, and here is the hole for the screw. Simply remove the protective cap and install it as if caressing with love, which will bring strength to the frames. Emmeline has put an end to a shortage once again. The tightening torque prescribed by the manufacturer is important here. During installation, make sure we are sitting straight in front of the assembly, as otherwise, the components could tip over. It should then lock in place. Strike while the iron is hot. When tightening, follow the manufacturer's order and of course, the important tightening torque. Always use a 9-point socket when mounting the new oil pan; they are included in the expert kit. There is a small quest here. We have the new star or the new oil pump cover with the gasket. The best thing to do is to spray it with our silicone spray and then mount it, always tightening the bolts in a cross pattern. There you go, it's done. Don't forget to reassemble the turbo hose; we removed it to make it easier to reach. We will now show you a simple method to check if the card is.

The printed circuit board is the part that caused the damage. You can easily check the continuity by placing the printed circuit board, removing by connecting a multimeter, then by searching for the corresponding pins and checking them. Here is an example: there is continuity here, so the contact is clean. But I can also check it again here. There are several possibilities on the board where I can follow the cable path. Our recommendation is that when the work is completed and everything is assembled, always perform a quick test of all control units to see if there are any defects that need to be eliminated. We hope this video has been informative for you. In this video, we wanted to show you how to disassemble the oil pan and how to access the mechatronics. This will then allow you to replace the electronic board, which we also provide. Once the mechatronics has been removed, we wanted to show you how to access this combined sensor, which in my opinion should be replaced at the same time as a prophylactic measure. Of course, there are many other reasons why a gearbox may not function correctly, but these are things that fall within the realm of gearbox repair. If you enjoyed this video, give us a thumbs up.

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Common Issues and Solutions for DSG Gearbox in Vehicles

The DQ250 type gearbox, found in many Volkswagen Group vehicles, often experiences oil sump leaks, which can be solved with an expert kit including a new sump, seal, oil, and filter.

Prior to work, it's important to conduct a diagnostic test to check for any errors in the automatic gearbox.

When disassembling the mechatronics, it's crucial to avoid damaging the vulcanized rubber seal and to only loosen the screws specified by the manufacturer.

Replacing the Electronic Unit and Sensor in a Car

To disconnect the connector, use a screwdriver to separate the printed circuit board.

When replacing the card, ensure that the contacts are straight and press it carefully into place.

Renew the seals on the plug, reconnect the electronic unit, and reinstall the mechatronics with the help of a colleague.

When replacing the combined sensor, remove the protective cap, install it with the correct torque, and ensure that it locks in place.

Finally, follow the manufacturer's order and torque when mounting the new oil pan and pump cover, and don't forget to reassemble the turbo hose.

Troubleshooting Printed Circuit Board Damage

The continuity of the printed circuit board can be easily checked using a multimeter to ensure the connections are clean.

It's recommended to perform a quick test of all control units after assembly to identify and eliminate any defects.

The video provides guidance on disassembling the oil pan, accessing the mechatronics, and replacing the electronic board and combined sensor for gearbox repair.

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