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

[omeydz]

Iv driven a a 400bhp Golf R20 DSG and its just sublime... Grinning ear to ear at the sound and power delivery. Okay my 1.4 turbo is a modest little brother of the Golf R but should still be nice to drive and sound dirtyyyy 

[th3_f15t]

You might want to watch this, I don't know if it'll help you but certainly worth knowing!

Clutch upgrade procedure for DSG, but if you end up having to sort the clutch out at least this might show you that it doesn't look to hard a job!

[omeydz]

Iv seen that video but very limited help as thats a 6 speed DQ250 DSG box with wet clutch.

To clarify I have DQ200 7speed dry clutch box:



The video is for 6speed DQ250 DSG wet clutch box (pic is of 4wd version Id say):

[th3_f15t]

Knowing how VW Group operate, I'd bet there's a fair few shared components so there may be a reasonable amount of theory to go off of to get it sorted. I've found that swapping engines in my mk4 V5 wasn't as bad as I thought it would be, as although the engines are totally different internally, all the supporting hardware (fuel lines, coolant connections ect.) still line up where my original engine ones do. VW Group clearly made them that way to save re-designing the whole engine bay so I'd bet the same logic was applied here. Despite being different systems I'd think the processes must be similar (but not identical)?

[omeydz]

Aye some truth to that I guess. Raw pricipals are similar.

Well hopefully have some more news later today (hopefully good). Hooking the battery up to charge on the way to work and Ill have a tinker with basic settings thisafternoon.

Wish me luck!

[omeydz]

So Iv tried to do basic settings and even that does not work despite following correct procedures this time.

Spoken to a VW tech mate of mine who suggests that the clutch or the actuating mechanism from the mechatronics is faulty in some way and that is nothing basic settings will fix.

With all this news, and the fact gearbox was unused dealer stock, Iv lost faith in this gearbox. I shouldn't be the one to fork out repairs for gearbox that should be fully working. Mechatronics are a 4 figure sum and clutch is around £400 for LuK Repset so its a false economy to try and repair it and I couldnt repair it with my limited expertise so gearbox specialist's labour would be on top.

Asked the seller to repair it or give me a full refund, awaiting their reply but either way the gearbox will have to come out again and await repair/look for a replacement box 

Iv come tooooo far to put the manual box back in. I knew something would inevitably go wrong due to my mistake but the gearbox seems to be the faulty piece of my DSG coversion project. FFS!

[th3_f15t]

All parts supplied as new or unused should legally have 3 months warranty so you shouldn't have to pay a penny.

[omeydz]

Hope so.

To be honest if its easily repairable I'd rather they repaired it as these gearboxes are quite rare and Im struggling to find a replacement from a scrappie. People are selling these used for more expensive than I got this one from dealer supply (maybe they knew it was faulty hence price but kept hush?!?!)

Just want a working gearbox now. Project has gone on long enough and I want to enjoy my hard work. Cannot believe of everything that could have happened, the gearbox itself was a culprit. 

[th3_f15t]

All part of the learning game mate, it is the worst at times but only makes the good times that much better. I have to do an engine and gearbox swap with my mk4 V5 so my chances of finding things don't work is much higher but you know what? Just enjoy the fun you have, even if it doesn't seem that way.

Would you rather be stuck in being one of the first people to do a manual-to-DSG swap, or sat about wishing you were?

[doylebros]

Firstly, ten out of ten for your commitment and effort on this challenge!

I assume you bought the box off a VW dealer? I wonder if their master tech would look at the issue since it's their part which is faulty and isn't an unrealistic request since you bought it in good faith!

[omeydz]

Yep I guess we are part of an elite and rare crew of bonkers people willing to take on such big challenges. Guess Im getting a bit impatient wanting to get my reward like a little kid. 

Im in Carlisle and gearbox was purchased in Crewe so Iv got to wait for them to get back to me first and see what they say. Talking to my own VW tech mate though, they are quite hands off when it comes to gearboxes. If its anything more than clutch or mechatronics they will just replace the entire gearbox along with a ridiculous bill for the owner/warranty company. Will see what they can do for me. Fingers crossed!!

[dazza]

Chin up mate u will get there one way or another.

Do the stealers have a different/better diagnostics system which can help you pinpoint the problem?

[omeydz]

Chin up mate u will get there one way or another.

Do the stealers have a different/better diagnostics system which can help you pinpoint the problem?

They have VAS diagnostic system. Iv got VCDS. In terms of diagnostics both tools will read the same error codes and perform same functions with respect to gearboxes so their gizmo wont help I dont think. Rekon the issue is with the clutch assembly or actuating mechanism between clutch and mechatronics. The fact I have no mechatronics errors means it is working as it should I presume?!

[dazza]

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?

[doylebros]

Yep I guess we are part of an elite and rare crew of bonkers people willing to take on such big challenges. Guess Im getting a bit impatient wanting to get my reward like a little kid. 

Im in Carlisle and gearbox was purchased in Crewe so Iv got to wait for them to get back to me first and see what they say. Talking to my own VW tech mate though, they are quite hands off when it comes to gearboxes. If its anything more than clutch or mechatronics they will just replace the entire gearbox along with a ridiculous bill for the owner/warranty company. Will see what they can do for me. Fingers crossed!!

Have you called any local firms like http://automaticgearboxrepairs.com/automatic-gear-box-repairs-carlisle and asked or called in to seek advice as there'll be visual and physical testes which will pin point this issue?