omeydz's Golf MK6 TSI - GTI/R20 Hybrid *DSG converted*

[omeydz]

When u got the box u said some oil leaked out. Doesn't this box have two oil systems? One for gearbox the other for mechatronic module?

Yes i drained both the mechatronics and gear oil circuits and filled with exact quantities of genuine oil and mechatronic hydraulic fluid.

[omeydz]

Yes Im going to call some while I wait for a reply. :)

[omeydz]

Update: Seller of the gearbox and they said they cannot repair, but will either collect gearbox for full refund or have offered me partial refund of £300 to keep the gearbox and contribute to repairs. Iv told them Im looking into each option and would let them know. In the meantime, Iv been doing some research and troubleshooting and decided to take the mechatronics off and see whats what. Ordered special tool to get it out properly without damaging anything.

Talking to gearbox specialists they think its either mechatronics or software issue but all are reluctant to help as they want nothing to do with a conversion. Iv decided its not software issue or else it wouldnt go anywhere at all. Doing some snooping in measuring blocks of the gearbox the displacement sensor readouts for selector fork for gears 1 and 3 is totally off the rest (reading about 0 meaning neutral) and is stuck in 1st or 3rd  ( I guess its 3rd and reads 12) and wont go in neutral. Reading the vw self study manuals with errors or abnormal readouts relating to this sensor causes the hydrualic circuit controlling this selector fork to be turned off as safety measure which explains my symptoms.

Talking to my vw tech mate, he thinks the mechatronics wasnt put on properly in the factory and selector actuator of the mechatronics not in the selector fork properly which I think has wedged it into 3rd.

So will whip off the mechatronics and hope this theory is correct. if everything is already in neutral Id suspect a dodgy displacement sensor and will have to get mechatronics repaired.

My hope is mechatronics wasnt put on right and Ill put it right and all will start working hopefully fingers x'd!

Wish me luck... venturing into the unknown some more lol!!

[th3_f15t]

Sounds reasonable that that's the issue here. My only concern is if you want to return it for a refund, you should tamper with it as they may refuse you a refund. However, I'd be more inclined to try repairs that you'd said as it's something you can then do for other people at a reduced cost (considering VW charge thousands for the job) so it's a good business plan to learn the DSG system fully.

And remember, you've done a conversion already so a gear box repair should be nothing!

[omeydz]

Ill make sure it goes on properly so nothing to show its been removed.

Hmm not sure I could do DSGs for other people.. be a miracle if I can fix my own lol! Anyway going to pop to the workshop and see if there are any free ramps to crack on with this.

[rich83]

Sounds like a mecha. Problem. 

[omeydz]

Yep mechatronics has to be.

No free ramps today but have earmarked one for Wednesday when Iv got day off to do this.

[mk05glf]

You are a very brave man for attempting this. Good luck

[omeydz]

I may be brave but I think im also foolish if I cannot fix the problem.

Got the day off tomorrow so wish me luck!

If my fix doesnt work itll be off to get the mechatronics repaired.

[omeydz]

No free ramps today. Too many MOT failures getting repaired  . Been promised one for tomorrow afternoon.

Anyway hooked up the vagcom to attempt to set everything in neutral which is protocol before removal of mechatronics to see what happens.

Heres screenshot of the Displacement sensors and the basic setting readouts.





Shows the displacement of 1st/3rd gear selector is well out of place of the target readings. Basic settings screen show its stuck in 1st gear and will not disengage into neutral through vagcom (which is what this basic setting does). All other selectors are close to their target values. Will be closer once Im able to sort the 1st/3rd selector issue so I can successfully do basic settings of bite points etc

So tomorrow Id expect the selector fork to be in 1st inside gearbox, and actuator of the mechatronics to be either attached to this selector fork or out of position completely.

[omeydz]

So got the mechatronics out today. Properly tight in there.. Had to remove the lower radiator hose and drain coolant to get it out ... Urgh!

It was indeed stuck in 1st and all actuators were positioned in their selector forks. All selector forks move and come to neutral readily by hand so its mechatronics that must be faulty as feared. So no point putting it back on the car with things repositioned as itll probably not work either.

So am sending off to ecutesting for testing, diagnosis and repair.. Fingers crossed it won't take long and straightforward repair. 



   

[Shoduchi]

Good luck with the repair! You deserve to have your conversion finished.

[doylebros]

So got the mechatronics out today. Properly tight in there.. Had to remove the lower radiator hose and drain coolant to get it out ... Urgh!

It was indeed stuck in 1st and all actuators were positioned in their selector forks. All selector forks move and come to neutral readily by hand so its mechatronics that must be faulty as feared. So no point putting it back on the car with things repositioned as itll probably not work either.

So am sending off to ecutesting for testing, diagnosis and repair.. Fingers crossed it won't take long and straightforward repair. 



 

Well in many ways that's a result as your testing and diagnosis pointed to what you found.

Once again 10 out of 10 for your efforts and sleepless nights.

[omeydz]

Thankyou everyone!  ..Hope mechatronics can be fixed easily (can't afford a replacement!) and I can fit it and that'll be that so I can

Too much time and effort is invested in all this to turn back but I won't lie, this has been testing testing my patience recently! 

[Tfsi_Mike]

So frustrating but hats off to you dude!