Continuous tracking of maintenance of Damai 7-speed dual clutch gearbox (concluded)

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 September 22, 2024
In the last half a month, the big DSG began to make a little bit of a moth. when starting at a low gear, it felt that the power output was weak and the shift was delayed. If you increase the throttle, the rotational speed will rise and the power output will be slowly put into gear, and then there will be a sudden frustration. After a sudden cough and collapse, the gear upgrade will continue to move forward, basically all in D1, D2, D3, and there is no problem with the high-speed gear.
The most extreme one, there is no power output directly in D1 gear, the throttle only increases the rotational speed, the car stays steady, and the effect is the same as hanging neutral, only after flameout and re-firing.
Why does a 100000-kilometer car start to have this problem now? The 4S store checked for most of the day and came to the conclusion that there may be something wrong with the gearbox control unit and it is estimated that it should be replaced and the price is expensive. Then looking through a large number of materials, I found that there are quite many problems with this gearbox of Volkswagen, the situation is highly similar, and the solutions are not the same. Some change the entire gearbox assembly, some change the bottom valve, some change a certain gear sensor, and some change the clutch plate of the gearbox. All in all, common failures of Volkswagen, some with warranty and some without warranty, different models and different guarantees.
Over the past few days, I am closely watching the details of the recurrence of the problem, and intend to collect more details of the fault, compare several more solutions, and initially judge that there must be an ultimate solution to this problem in the near future. otherwise, I will be left on the highway and my grandmother will not be in love with my uncle.
-the dividing line three days later-

The situation is getting more and more serious. after careful observation (dare not be careful, even the start may be dead), it is found that the problem is only between D1, D2, D3, and can be operated at will after rising to D3. Basically no frustration (I don’t know if the problem will expand in the future).

It is almost impossible to start climbing, because it needs to step on the throttle and the speed comes up, but it does not change gears, resulting in insufficient power output, and the car has to gasp on the slope unless more than three gears pass quickly.

The start should be super gentle, the first floor to second gear should be super gentle, and the second floor to third gear should be super gentle. If you hang up in third gear, you can breathe a sigh of relief and drive happily. How gentle is it? Basically at a speed visible to the naked eye, the numbers on the speedometer jump word by word, until the jump to 30 is almost a successful shift, each shift, the basic speed will be close to 2000 rpm will switch, the back of the car is sorry, just treat me as being courteous to pedestrians.

During this period, I read all the articles and posts about Volkswagen’s seven-speed double clutch gearbox. I learned in detail about the structure and installation sequence of DSG gearbox, but I could disassemble it directly. During this period, when I waited for a red light, I automatically changed neutral twice and had to turn off the engine and start again before it was solved. No, I had to go to the 4S store to fully check it. The problem became more and more serious.

-three days later, three days later–

The level of 4S stores of imported Volkswagen is really uneven. As a result, the explanations of the three stores are different, but the more unified point is: the problem is rare, never encountered, can only check the computer, can not repair.

I’m dizzy. I can check the fault code by computer, but it’s killing me if I can’t come up with a credible solution, but the repairman admitted that because the market for this car is too low, the problem is not as easy to reproduce as other cars such as Tuguan. With regard to gearbox problems, especially Matway’s gearbox, I encounter at most one car a year. As a result, this is not my car.

In the back and forth of several stores, they recorded and observed carefully and found that they could not open any more, because there were two more dead fires in the middle, and the key was that one of them finally flashed the sign of “small wrench”. Although the fault disappeared after starting the fire again, it is obvious that the problem is getting more and more serious, so let’s send it to the store for repair.

During this period, consult all professionals and non-professionals, including technicians, parts merchants, after-sales, imported Volkswagen national customer service, car friends. The problems and solutions are as follows:
1. The fault code can not determine whether there is a problem in the mechanical transmission part. To be on the safe side, it is necessary to remove the wave box, and some stores say that it cannot be removed, which means that the price starts at 8K.
2. if it is a mechanical and electrical unit or valve body failure, the basic 4S store does not have the maintenance capacity, but it is recommended to replace the imported parts, not to mention the purchase of goods for 30 days.
3. There may be alternative parts in China, but the quality varies, including auxiliary factory parts, dismantled parts, maintenance parts, etc., the warranty period varies, some can be guaranteed for one to two years, some can only guarantee the car or one week, of course, the price is also very different.
4. Wave boxes can be disassembled and repaired by companies specializing in wave boxes, especially in Guangdong, but there are no channels to contact them.
5. Gearbox assembly, clutch friction disc, valve body, sensor, electromechanical unit are all suspected, the problem is big or small, it all depends on the professional ability, the customer’s face is covered by XX.

I chose a 4S store that I thought was a bit more professional to send it for repair, and let the store examine it carefully and come up with a solution.

To be continued.

— the final dividing line–
After a long wait, more than ten days later, it was finally done, at least for now.
First of all, the fault code is not completely credible. After opening the wave box, we found that the valve body was not damaged, and the imported parts did not need to be bought. At that time, it would be miserable to change parts according to the simple and rough change in the store. If the problem was not solved, more than 20,000 yuan would be used for drifting.
The problem lies in the clutch friction plate, there is wear, the worn surface is partially exfoliated and ablated, the corresponding friction plate is replaced, the computer test is passed, and then the car is tested, and the problem does not reappear.
This is the advantage of taking apart all the wave boxes. If you do not take them apart, you will not be able to find the hardware damage and fault in the maintenance computer. It may misreport and mislead the maintenance personnel (experience is really important).
However, the quotation for the comprehensive disassembly and overhaul of the wave box is also not cheap, anyway, how much less is it, and 20,000 yuan is still needed. It is estimated that if it had been sent directly to the wave box maintenance company at that time, a 50% discount should be able to be settled.

After tearing it apart, I finally breathed a sigh of relief. At least now I can run happily on the road again. Who knows when this fragile clutch box will lose its temper again? I’d better take care of it. During this period, I checked a lot of information and found that slow-moving congestion and frequent starting snails in the city are also a cause of such failures. I don’t know whether it is true or false, but it is also a fact that frequent clutch shifting during traffic jams increases losses.

After finishing, I went on my big ski trip.