02E Gearbox Technology

Diagnosis & Solutions – Technical Support 2012

 02E TRANSMISSION FAULTS

Diagnostics – Measuring value blocks - vehicles with DSG gearbox

A correct diagnosis of faults on 02E DSG gearboxes can be carried out using selected measuring value blocks of gearbox electronics.

Therefore, all measuring value blocks (idling when vehicle is stationary in mode P or N or D) is to be used when there is a suspicion that a
fault of the transmission is involved.

In MVBs, the following information may be read out:

• Identification of SW and HW version of the gearbox CU (Mechatronic).

• Current operating values (oil pressure values in the Mechatronic, position of the individual gear adjusters, condition of the clutches, RPM
of the individual shafts, selector lever position etc.)

• Continuous values recorded under operation (driving times in various driving modes, clutch temperatures under operation, driving time in
all temperature modes and warning modes etc.)

• Detailed ambient conditions when two last faults occurred

All gearbox MVBs can be collected via the GFF test plan
02E TRANSMISSION FAULTS
Complaint: Only 2nd gear can be shifted into, which in this case is also used to drive off.
Reversing is not possible.
Emergency program: Partial gearbox 1 switched off, partial gearbox 2 OK.

Only gears 1 and 3 are still engaged (with interruption in drive).

Reversing is not possible.
Emergency program: Partial gearbox 2 switched off, partial gearbox 1 OK.

Fault memory entry: 17160 Pressure regulating valve 2 -N216 open circuit/short to earth
18115 –x Fault in mechatronics unit
18232 Pressure regulating valve 3 -N217 open circuit/short to earth
18237 Pressure control valve 4 -N218, open circuit/short to earth

Cause: In the mechatronics unit, electrical connections are destroyed by over-voltage. As a result,
certain valves can no longer be driven.

Repair note: The connections in the Mechatronic unit have been improved to resist electrical damage. In cases as above the
mechatronics unit should be exchanged.
02E TRANSMISSION FAULTS
Complaint: Only 2nd gear can be shifted into, which in this case is also used to drive off.
Reversing is not possible.
Emergency program: Partial gearbox 1 switched off, partial gearbox 2 OK.

Only gears 1 and 3 are still engaged (with interruption in pull).

Reversing is not possible.
Emergency program: Partial gearbox 2 switched off, partial gearbox 1 OK.

Fault memory entry: 18222 Pressure regulating valve 1 -N215, open circuit/short to earth
18227 Pressure regulating valve 2 -N216, open circuit/short to earth
18223 Pressure regulating valve 1 -N215, short to positive
18228 Pressure regulating valve 2 -N216 short to positive

Cause: Contamination or dirt particles in the gearbox oil can cause the pressure regulating valves to stick briefly.
This sticking may be the reason for the logged fault codes.

Repair note: If one of the faults named is sporadic, the first time it occurs the fault memory must be read out and deleted. Since the
gearbox oil is continually cleaned by the pressure oil filter, it is highly probable that the fault will not occur again. If one of these faults
reoccurs, the mechatronics unit must be exchanged.
02E TRANSMISSION FAULTS
Complaint: Inverted gear display in instrument cluster.

Fault memory entry: 17115 1. gear wrong transmission ratio

17116 2. gear wrong transmission ratio
17117 3. gear wrong transmission ratio
17118 4. gear wrong transmission ratio
17119 5. gear wrong transmission ratio
17113 6. gear wrong transmission ratio

17106 Gearbox output speed sender 1 -G195, no signal

18201 Gearbox output speed sender 2 -G195, no signal
19143-8 Fall-off of rpm on input shaft 1 or input shaft 2 detected.

Cause: RPM sensor G195 and G196 defective, Hall sensor electrical damage (sporadic short)

Repair note: If one of the faults logged is sporadic, the first time it occurs the fault memory must be read out and deleted. It is highly
probable that the fault will not reoccur. If one of these faults reoccurs the mechatronics unit must be exchanged.
02E TRANSMISSION FAULTS
Complaint: Only 2nd gear can be shifted into, which in this case is also used to drive off.
Reversing is not possible.
Emergency program: Partial gearbox 1 switched off, partial gearbox 2 OK.

Only gears 1 and 3 are still engaged (with interruption in pull).

Reversing is not possible.
Emergency program: Partial gearbox 2 switched off, partial gearbox 1 OK.

Fault memory entry: 17130 Pressure control valve 1 -N215, open circuit/short to earth
17160 Pressure regulating valve 2 -N216, open circuit/short to earth
18232 Pressure regulating valve 3 -N217, open circuit/short to earth
18237 Pressure regulating valve 4 -N218, open circuit/short to earth
19155 Pressure regulating valve 5 -N233, open circuit/short to earth
19164 Pressure regulating valve 6 -N371, open circuit/short to earth.

Cause: Contact problems in the power supply to the valves listed above.

Repair note: If one of the faults named is sporadic, the first time it occurs the fault memory must be read out and
deleted. Take a test drive. The gearbox oil temperature should exceed 90 °C. If the fault reoccurs, the
mechatronics unit must be exchanged.
02E TRANSMISSION FAULTS
Complaint: Judder, erratic gear shifting

Fault memory entry: 17252 - Transmission pressure adaptation at impact upper limit exceeded

Cause: extreme levels of enhancement chip tuning

Repair note: check vehicle if possible for TD1 in vehicle data online (PR codes) info. Please reference Desktop bulletin regarding
TD1 information.
02E TRANSMISSION FAULTS
Complaint: Vehicle has no propulsion (drive)

Fault memory entry: 18203 -x Signal for road speed, open circuit
17106 Gearbox output speed sender 1 -G195, no signal
18201 Gearbox output speed sender 2 -G196, no signal
Sender arm with G195 and G196

Cause: 18203 -x, Failure of both gearbox output rpm from sensors G195 and G196.

17106,18201 Diagnosis too sensitive, plausibility check of output rpm 1 or output rpm 2 to average front CAN drive.
wheel rpm. Possible fault in brake electronics. Both entries often occur simultaneously

Repair note: 18203 -x 1. Delete fault memory, then take a test drive. MWB 8 displays rpm.
2. If the 18203-x reoccurs: exchange the mechatronics unit.

17106 and/or 18201 check brake electronics CAN signals. Are the brake electronics on the CAN bus? Are faults
in the brake electronics fault memory relating to the wheel rpm sensors? Delete all faults,
then take a test drive. If one of the faults 17106 or 18201 reoccurs, the mechatronics unit
must be exchanged.
02E TRANSMISSION FAULTS
Complaint: Sporadically delayed application of power, then driving off with juddering

Fault memory entry: 17100 Gearbox input speed sender -G182; implausible signal
18148 Clutch temperature monitoring

Cause: Poor sensor connection or signal interference.

Repair note: Check whether the plug of the gearbox input rpm sender is correctly seated. If the plug is correctly
seated, it can be assumed that the sender or the cables are defective. If the area of the sender proves
to be the cause of complaint, the mechatronics unit does not need to be exchanged. If the error occurs
although no fault in sensor -G182 can be determined, exchange the mechatronics unit.
02E TRANSMISSION FAULTS
Complaint: Jerking on pull away when vehicle is warm. In most cases, no fault is stored in the fault memory of the Mechatronic unit.

Cause: An internal fault of the Mechatronic control unit. Wear on clutch control valve mountings means the curve for controlling the
pulling away clutch can’t be maintained.

Repair note: Check the date of Mechatronic production. Material changes for mounting of the clutch control valves have been made.

Checking procedure: Self diagnosis 02 – Gearbox, 011 – Measuring value block - Channel 54

H07A0001 - J21N0560 H = year 2007; 07 = calendar week , J = year 2008; 21 = calendar week

Measure: If you find out that the production date lies in the above range (H07 – J21), replace the Mechatronic.
After the replacement, carry out the basic setting and adaption test drive.
02E TRANSMISSION FAULTS
Complaint: Communication faults

Fault memory entry: 18262 Drive train data bus defective

18274 Drive train data bus missing messages

18256 Please read out engine control unit fault memory, fault entry only.
18258 Drive train data bus missing messages from engine control unit
18260 Drive train data bus, implausible message from engine control unit

18255 Please read out ABS control unit fault memory, fault entry only.
18259 Drive train data bus missing message from ABS control unit, fault entry only.
18261 Drive train data bus, implausible message from ABS control unit, fault entry only.

18250 Please read out instrument panel fault memory, fault entry only.
18270 Drive train data bus missing message from instrument panel, fault entry only.
18082 Drive train data bus, implausible message from instrument panel, fault entry only.

18036 Drive train data bus, missing message from steering angle sender, fault entry only.
18273 Drive train data bus, missing message from central electronics unit,
fault entry only.
18275 Drive train data bus, missing messages from steering column electronics -J527,
fault entry only.

Cause: Lies in communication with control units whose information is need by the gearbox control unit
for proper operation.

Repair note: Don’t just consider the gearbox for the fault. Please look at the ECU listed in the fault description.
 02E TRANSMISSION FAULTS

Complaint of judder:
This test can be used to determine if a complaint of judder on pull away is caused but a clutch issue. By allowing the
gearbox to pull away in second gear rather than first gear you may find the judder on pull away is reduced or
removed. If this is the case then the judder is caused by K1 clutch and not the Mechatronic control.

Test:
• Insert the gear “D” and then switch the selector lever from D to R three times.
• You should then be able to start in the second gear (dash will only display ‘2’ once the vehicle is moving).
• At the start pay attention that the engine speed is a little increased.
• Pull away slowly

Repair:
If the complaint is now removed, you are looking at clutch creep and the multi-clutch should be considered for replacement.
02E TRANSMISSION FAULTS
Complaint: Clutch judder/delay in drive

Cause: Clutch, defective centrifugal oil compensator

Test:
• Vehicle is at rest on the level, brakes may not be actuated.
• Engage driving position N.
• Increase engine rpm to upper rpm limit, maintain this for 5 seconds.
• Repeat the cycle 20 to 30 times to ensure there is no defect.

Result:
How are defective double clutches recognised?
If the vehicle starts to creep backwards from about 4000 rpm,
the test must be terminated. This avoids further damage to the 3rd gear synchronisation.

Repair: Replace the clutch

02E TRANSMISSION FAULTS
Complaint: When rolling forwards from a standstill, a juddering can be felt in the drivetrain (creep juddering).

Cause: Creep juddering results from a non-uniform torque < 1Nm which
results from different thicknesses in the material of the clutch plates.

Repair work: Observe mandatory notification.

Replace double clutch.

Action: Optimisation of production at supplier. The clutch plates are "matched" by the manufacturer, i.e. they are
repeatedly turned and fitted until the lowest possible non-uniform torque exists. The clutch plates
are then sent paired in the clutch cage as original parts. When fitting an original clutch, care should therefore be
taken that the clutch plates do not fall out of the clutch cage. The fitting position of the clutch plates is not marked.

If a clutch plate assembly has separated, correct reassembly in the workshop can
not be guaranteed. There is a danger that the new original parts clutch judders
when driving off. Creep juddering.
 Mechatronics unit, fault analysis

02E Transmission Faults

Complaint: Noises, juddering, gearbox does not shift smoothly, no or delay in drive.

Fault memory entry: No fault memory entry present.

Cause: The causes of complaints can be found in many different areas of the vehicle such as the engine or the suspension.
Analysis of mechatronics units that have been exchanged, and experience, show that changing the mechatronics
without a fault memory entry being present generally has no influence on the complaint.

Repair note: If no fault memory entry exists, and uncertain on repair.

If in doubt contact the Technical Support via DISS Technical enquiry.

Please include an accurate description (refer to the separate attachment).

of the complaint and all transmission MVB in P/N and engine running via the GFF test plan.