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General VW Discussion This is a place for General VW topics (the company, not your vehicle). General topics about a specific vehicle should be posted in the General TDI Dicussion Forum sections for that vehicle platform. A4, A3 & B4, B5, etc.

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Old August 6th, 2006, 11:02   #1
wjdell
Veteran Member
 
Join Date: May 2006
Location: Central Florida
Fuel Economy: avg. 41.93 high 46.32 low 34.6
Default DSG "Direct Shift Gearbox" owners data base

Owners of the DSG transmission, in any make or model. We encourage you to register your DSG here. Please add your transmission data in the following form. Add any comments you have to your original post - PLEASE, I am trying to keep this easy for people to scan. You can post information if its relevant to all owners. The data you put in your post should be related to, service, fluid changes, problems, and the resolutions. You can write about you personal experiences with the DSG. Please try to recruit other members to join also. We are some of the first to have F1 technology in our street car transmissions. In the end I believe this transmission will be a winner.

Thank You
WJ Dell
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ ~~~~~
DATE:
Name:
Year:
Make:
Model:
Date of auto production: - " usually month and year " unless you know the day
Engine code: "in your manual"
Transmission Code: - “located in owners manual next to engine code
Date of DSG Production: - “ located on top of trans just below and beside the battery – is visible with flashlight”
Purchased, New or Used:
Miles when purchased:
Current miles: - " update this whenever you chosse "
Area of country: - “ southeast USA, - Melbourne Australia "
Fuel Statistics: - " best/average/worst only please " update this whenever you choose

List dates of any problems and or resolutions. Feel free to list any input you might feel will be helpful with the DSG data base.

If you find interesting articles post the link only

~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
DSG fluid and filter maintenance parts needed
6 liters of DSG fluid part # G052182A2 "could be FUCHS"
1 DSG filter part # 02E305051B (now superceded by last letter C)
1 DSG filter seal part # N91084501
1 Gasket. Part # N 043 809 2.

Suggested tools
14 mm HEX for the drain/fill plug.
8 mm HEX for tube.
VAS 6262.

This tool could be substituted by buying a DSG drain plug and drilling it out. You can then insert a hose nipple into the plug threaded, or you could have it welded. I think the nipple should be the clamp type so the hose can easily be removed for the fill checking. The plug on the bottom of the DSG is 25 mm in diameter and has a 1.5 pitch. I suggest clear hose and many part stores have this. A clean pan to drain the DSG into. I say clean as a inspection of the drained fluid is a good idea as it may show signs of problems.
NOTE

Do not use funnels or hoses that have any other type of oil. Contamination! - The manual is specific about this. Additive contamination may be very harmful to your DSG. Periodic changes are smart and flushing is not reccomended because of contamination from other oil and additives.

Vag-Com is needed to get a running temperature of 35 to 45 C for refill. You could possibly use another means but I am not sure were you would put the test probe.

Its best to do this on a level hard surface. You need not remove the battery to perform the filter change. I think I would prefer to use 4 jack stands or two ramps and 2 jack stands. Keep the vehicle level, that will be critical for proper fill.

1. Remove the engine covers.
2. Disconnect the Mass Air Flow harness
3. Disconnect vent hose and air guide hose
4. Open spring clamp on air guide hose remove from tube
5. Remove filter housing
6. Remove the bottom engine cover
7. Place clean receptacle under DSG
8. Reaching under the battery unscrew filter housing and tilt slightly to empty
9. Remove filter and note is position suction collar is down
10. Remove o-ring seal
11. Install new o-ring seal with coating of fluid
12. Install new filter suction collar down and housing tighten to 15Nm to 20 Nm.
13. Install filter housing
14. Install Mass air Flow harness
15. Install air guide hose
16. Install vacuum hose
17. Connect air guide hose with spring clip
NOTE : There maybe one or two plugs depending on your production date. The rear drain plug and the front is the fill plug. If you have no drain plug than the Fill plug doubles as both. If you have only the one plug than you must remove the snorkel to drain. I suggest you catch all fluid in a clean container and measure !
18. After the fluid is completely drained replace snorkel, 3 Nm.
19. Attach VAS 6262 and pour 5.5 litres of fluid into DSG.
20. Using VAG-COM check DSG temperature.
21. Start engine - do not run engine when trans is empty !!
22. Depress brake select each position for min of 3 seconds. R-N-D-S moving selector to park and DO NOT SHUT OFF THE ENGINE.
23. After the DSG reaches the desired temperature disconnect hose from nipple or adapter coupler on VAS 6262 and allow excess to drain out. When there is only a drip promptly remove adapter and replace the check plug.

NOTE : There will be a cooling pulse every 30 seconds and this is not a indication of overfill. The system is actually idiot proof. It may be easier to cool the fluid before use. CHECK FOR LEAKS and remember clean is the WORD.

Link to the DIY, DSG oil and filter change.

NOTE - Fuch's shows the DSG interval as 60k km or 48 months - I am sure that corrosion may be a issue, and a fluids abilty to resist this is depleted over time.
http://forums.tdiclub.com/showthread...39#post1639639

UPDATE " DMF" DUAL MASS FLYWHEEL

Vw has a new part to supercede the old flywheel. There must have been a problem. The old part is and the new - here is what the parts supplier shows
" Supersession Information Part number 03G105266AP was superseded by part number 03G105266BE."

VOA of VWG052182A2 DSG fluid

Fe Iron --------------------- 0
Al Aluminum --------------0
Cu Copper ---------------- 0
Si Silicone ---------------- 3
Na Sodium --------------- 3
Mo Molybdenum ------- 0
Mn Manganese --------- 0
B Boron ---------------- 118
Sb Antimony ------------- 1
Ca Calcium ------------- 47
P Phosphorus -------- 265
Zn Zinc --------------------- 9
Water Volume ----------- 0.00
Viscosity 100C ---------- 7.50
ISO Code ------------- 21/18/13 - should be better
4 Micron ----------------- 13,068
6 micron ----------------- 1438
10 micron ------------------ 127
14 micron -------------------- 52
21 micron -------------------- 9
38 micron --------------------- 1
70 micron --------------------- 0
100 micron ------------------- 0
TAN ------------------------- 1.00

Last edited by wjdell; November 1st, 2008 at 19:25. Reason: updated
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Old August 6th, 2006, 11:04   #2
wjdell
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Join Date: May 2006
Location: Central Florida
Fuel Economy: avg. 41.93 high 46.32 low 34.6
Default DSG " Direct Shift Gearbox "

Date:08/05/06
Name:WJDell
Year:2006
Make:VW
Model:Jetta
Date of auto production: 12/05
Engine code: BRM
Transmission Code: HQN
Date of DSG Production: 07/19/05
Purchased, New or Used: New
Miles when purchased: 34
Current miles: 35,000
Area of country: southeast USA
Fuel Statistics: 47.68/42.7/35.3

DSG fault code. When approaching a stop quickly it downshifted abrutly and the trans began flashing. I had to shut the motor off to clear. The next day I found this stored fault code.

Address 02: Auto Trans
Part No SW: 02E 300 042 H HW: 02E 927 770 AE
Component: GSG DSG 070 0913
Coding: 0000020
Shop #: WSC 00066

1 Fault Found:
18227 - Pressure Control Valve 2 (N216): Open or Short to Ground
P1819 - 008 - Implausible Signal - Intermittent
Freeze Frame:
Fault Status: 00101000
Fault Priority: 0
Reset counter: 38
Mileage: 21892 km
Time Indication: 0

The trans never failed and is working well 200 miles after this incident. I cleared the code and all is well. I have run software but all seems normal. It will go to the dealer for evaluation this week. The P1819 in the Bentley is as follows

Replace Direct Shift Gearbox (DSG) mechatronic J743 6 Spd. Direct Shift Automatic Transmission 02E Front Wheel Drive - Repair Group 34.

Went to Stuart Florida VW - and a german gentleman named Helmutt gave it a clean bill of health - So lesson learned do not clear the codes even though I printed and saved to file they may only use 5051 to report to VW. It happened once and it will again I think so then I will leave the code in and let Helmutt decide.

DSG UOA 20,000 miles --- Second UOA 52,000
Fe Iron --------- 26 -- 23
Al Aluminum -- 1---- 1
Cu Copper ---- 8 ---- 6
Si Silicone --- 34 --- 19
Na Sodium ---- 3 ---- 2
Mo Molybdenum - 2 - 1
Mn Manganese - 5 -- 3
B Boron -------- 73 ---- 86
Ca Calcium --- 40 ---- 36
P Phosphorus -- 226 -- 228
Zn Zinc ---------- 22 ----- 14
Viscosity 100C 6.80 ---- 6.40
Ferro Small ---- 19 ---- N/A
Ferro Large ---- 34 ---- N/A
TAN ------------ 0.92 ---- 1.07
PQ Index ----- N/A ------ 10

Vag - Com - 340.00
Bentley Manuals 2 - 160.00
Vas 6262 - 95.00
20k 1st OCI fluid, filter, gaskets with UOA total cost - 167.00
52k 2nd OCI fluid, filter, gaskets with UOA total cost - 145.00
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Post your UOA data in the TDI UOA Database thread
http://forums.tdiclub.com/showthread.php?t=205814


~ USED OIL ANALYSIS ~ http://forums.tdiclub.com/showthread.php?t=190958
~
1.9 PD Jetta V ~ pkg 1 ~
DSG ~ 17" VV ~ 36/34 psi ~
ULSD ~ DG-BP90 - speed 39.2
hwy/city 83% / 17% ~
elev 58 ft / temp 72 F / humidity 76% ~ MPG 48.3 / 42.8 / 35.6


Last edited by wjdell; September 15th, 2009 at 22:22. Reason: form correction
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Old August 7th, 2006, 14:48   #3
overbite
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Join Date: Mar 2004
Location: Eagle Lake, MN
TDI(s): 1996 passat
Fuel Economy: 49/44/27
Default

DATE:8-7-2006
Name:0VERBITE
Year:2006
Make:vw
Model:jetta
Engine code:
Transmission Code: -
Date of Production: -
Purchased, New or Used:new
Miles when purchased:76
Current miles:~15,000
Area of country: - south central Minnestoa
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1999 F250 Powerstroke (the wife's)
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Old August 8th, 2006, 18:01   #4
jocat54
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Join Date: Aug 2006
Location: San Antonio Texas
TDI(s): Jetta
Default

Date: 8-8-2006
Name: Jocat54
Year:2006
Make:VW
Model:Jetta
Engine Code:BRM
Transmission Code:-
Date of Production:-
Purchased, New or Used: New
Miles when purchased:15
Current Miles:66000
Area of Country:South Central Texas. San Antonio

ocassionally no throttle response from standing start-seems to happen more after driving for a while. May be my driving habit- wife says it never does it to her.
_______________________________________
2006 Jetta TDI-wifes
2004 Chevy Crew Cab 2500
1993 K1500-Love this truck

Last edited by jocat54; July 8th, 2008 at 21:33.
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Old August 9th, 2006, 12:49   #5
tomo366
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Join Date: Jun 1997
Location: Kensington, Maryland USA
Default

DATE:08/09/2006
Name:Tom Walker
Year:2006
Make:Volkswagen
Model:Jetta TDI
Engine code:BRM
Date of auto production: April 25,2006
Transmission Code: - HXU
Date of Production: - 2/20/06
Purchased, New
Miles when purchased:40
Current miles:3828
Area of country: - Mid Atlantic

I don't know for sure, but I think this car may have had another Transmission put into it.....
It was held at the Plant for nearly a month after the DSG Clip problems arose...
It has a different looking sticker on it.
No problems though.
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Great friend and supporter of TDICLUB
2015 Jetta TDI SEL Tornado red
2014 BMW 328D XDrive Glacier Silver
2001 Jeep Cherokee silver

Last edited by tomo366; August 10th, 2006 at 04:35.
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Old August 11th, 2006, 09:13   #6
Vipervnm
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Join Date: Jul 2006
Location: Kingwood, NJ
Fuel Economy: Best: 48.2 mpg, Avg: 43 mpg
Default

Date: 08/11/06
Name: Ian
Year: 2006
Make: VW
Model: Jetta
Date of auto production: 02/06
Engine code: BRM
Transmission Code: HQN
Date of DSG Production: -
Purchased, New or Used: New
Miles when purchased: 6
Current miles: 48,000
Area of country: Central NJ, USA

UPDATE: The car is starting to shift unusually rough at an increasing rate. It used to do it on ocassion under WOT, but now it occurs regardless of the RPMs or pedal position. Starting to regret choosing the DSG.

UPDATE 2 (10/17/07, 37,000 miles): Started the car one day and all the weird shifting problems disappeared. It's been nearly 7 months now and the problems haven't resurfaced. Electronic phantoms are so strange.

UPDATE 3 (8/11/08, 48,000 miles): Everything is going well. No codes or problems after fluid change 8,000 miles ago. Good stuff.

UPDATE 4 (12/31/08, 52,000 miles): Out of warranty now. The car keeps getting smoother and smoother. Just got a clean bill of health at 49,998 miles! I wish I could have made at least one warranty claim. Looking forward to several more years and tens of thousands more miles!
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'06 Jetta TDI DSG "Diesel Thunder" RC1+ 205k mi
'00 Jeep Wrangler Sport 4.0 5-sp 185k mi
'97 Jeep Wrangler Sport 4.0 5-sp 137k mi
'46 Willys CJ2a 2.2 L-head "Go Devil" 3-sp 64k mi

Last edited by Vipervnm; December 31st, 2008 at 09:28.
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Old August 12th, 2006, 20:12   #7
bockegg
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Join Date: Apr 2006
Location: PA
Default Diesel Dog

DATE: 8/12/2006
Name: Mike
Year: 2006
Make: Volkswagen
Model: New Beetle
Date of auto production: - 3/2006
Engine code: BEN
Transmission Code: - HXV
Date of DSG Production: - 12/12/2005
Purchased, New or Used: New
Miles when purchased: 210
Current miles: 3,985
Area of country: - Huntingdon, PA

Last edited by bockegg; August 13th, 2006 at 19:45.
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Old August 12th, 2006, 20:48   #8
gleep
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Join Date: Jun 2001
Location: Idaho
Default

DATE: 08/12/2006
Name: gleep
Year: 2006
Make: VW
Model: Jetta
Date of auto production: ???
Engine code: BRM
Transmission Code: - HXU
Date of DSG Production: - 04/11/2005
Purchased, New or Used: new
Miles when purchased: 31
Current miles: 13,412
Area of country: - South Central Idaho


gleep
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2006 Jetta TDI - Platinum Gray / Anthacite Leather, Pkg 2 w/DSG, 17" Vision V wheels

Last edited by gleep; August 13th, 2006 at 08:14.
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Old August 13th, 2006, 07:18   #9
eagle
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Join Date: Apr 2004
Location: North Carolina
TDI(s): 2006 Jetta
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Name: eagle
Year: 2006
Make: VW
Model: Jetta
Date of auto production: 6/06
Engine code: BXR
Transmission Code: HXU
Date of DSG Production: 016/09/02/06
Purchased, New or Used: New
Miles when purchased: 8
Current miles: 6,182
Area of country: NC, USA
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Hers: was a 2006 Jetta TDI DSG pkg2 (now sold)
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Old August 19th, 2006, 11:32   #10
route66
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Join Date: Aug 2006
Location: Chandler, AZ
Default

Date:08/19/06
Name:Tom
Year:2006
Make:VW
Model:Jetta TDI
Date of auto production: 07/06
Engine code: BRM
Transmission Code: HXU
Date of DSG Production: tbd
Purchased, New or Used: New
Miles when purchased: 33
Current miles: 4075
Area of country: Arizona, USA
Fuel Statistics: 38-39ish, but I don't baby it and primarily drive in town.

Will update occasionally - This car ROCKS!!!!!!

Still no problems as of this edit/update. Do notice some "roll back" (a few inches, but noticeable) when parking on an incline. Of course I set my brake but have not seen this in other automatic transmissions I have driven.
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Last edited by route66; January 3rd, 2007 at 10:15.
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Old August 19th, 2006, 13:04   #11
Mark of Diesel
 
Join Date: Nov 2001
Location: Kalkaska Mi.
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Date: 08/19/06
Name: Mark
Year: 2006
Make: VW
Model: Jetta
Date of Auto Production: 12/2005
Engine Code: BRM
Trans Code: HXU
Date of DSG production: 083/04/08/05 (from tag on trans)
Purchase: New
Miles when purchased: 30
Current Miles: 9000
Locale: Michigan
MPG: Mid 40s
Problems: Hesitation off stops but we're adjusting. No other issues.
BTW, I found the engine and trans codes on a sticker in the spare tire well in the trunk.
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Old August 19th, 2006, 20:29   #12
Maven
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Join Date: Aug 2006
Location: Eastern Iowa
Fuel Economy: Little shy of 40 overall average.
Post

~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ ~~~~~
DATE:8/19/06
Name:Maven
Year:2006.5
Make:VW
Model:Jetta TDI
Date of auto production: - July 2006
Engine code: BRM
Transmission Code: - HXU
Date of DSG Production: - Haven't crawled in there yet
Purchased, New or Used:New
Miles when purchased:11
Current miles: - 850
Area of country: - Central Midwest (Iowa) USA
Fuel Statistics: - 48.5 Best, 42 AVG, 42 Worst
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Old August 22nd, 2006, 21:12   #13
whitacre
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Join Date: Dec 2005
Location: Spring, Texas
Fuel Economy: 43.4
Default

Date:08/22/06
Name:Whitacre
Year:2006
Make:VW
Model:Beetle
Date of auto production: 01/06
Engine code:
Transmission Code:
Date of DSG Production:
Purchased, New or Used: New
Miles when purchased: 284
Current miles: 16,105
Area of country: Houston Texas USA
Fuel Statistics: 47 MPG highest Highway.
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Old August 25th, 2006, 07:25   #14
tfink
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Join Date: Aug 2006
Location: Clayton, OH
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Date:08/25/06
Name:tfink
Year:2006 1/2
Make:VW
Model:Jetta
Date of auto production: July '06
Engine code:
Transmission Code:
Date of DSG Production:
Purchased, New or Used: New
Miles when purchased: 21
Current miles: 700
Area of country: Dayton, OH USA
Fuel Statistics: 45 MPG highest Highway.

Last edited by tfink; September 2nd, 2006 at 19:09.
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Old August 25th, 2006, 15:55   #15
2004STARWARSTDI
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Join Date: Oct 2004
Location: LAKELAND, FL
Default

~~~~~
DATE: 8/25/2006
Name: Frank
Year: 2006
Make: VW
Model: Jetta TDI
Date of auto production: - Jan 2006
Engine code: BRM
Transmission Code: - HXU
Date of DSG Production: 036/23/11/05
Purchased, New or Used: NEW
Miles when purchased: 50
Current miles: - 19000
Area of country: - “ southeast USA, Lakeland, Fl
Fuel Statistics: - " best/average/worst 48.3/41/39

Last edited by 2004STARWARSTDI; May 21st, 2009 at 15:29.
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