The latest technology gearboxes are increasingly fitted with mechatronics that can take clutch and gear shifting operations completely off the driver’s hands.

 

Perhaps the best-known example of this is the DSG 6 transmission used by VAG on a variety of popular Audi, Seat, Skoda and VW models.

 

The DSG, or direct shift gearbox, works many times faster than a conventional gearbox, partly because the next gear is already pre-selected, due to a DSG 6 having two clutches. Similarly, there are also two primary shafts, effectively meaning two partial gearbox units available that work together in a single housing.

 

ACtronics has a comprehensive article on its website that explains the workings of DSG, including a video. The system is controlled by a Transmission Control Unit (TCU). This is the DSG transmission’s brain and consists of an electronics unit, which uses vehicle parameters and sensor values to make the decisions as well as actuators that can operate the built-in clutch and shift solenoids.

 

These TCUs are known to develop faults with solenoid valves and sensors, which can lead to erratic gear changes or gear change failure.  ACtronics has studied these problems and has been able to find several causes inside the TCU. A special overhaul routine has been developed to repair the TCU while maintaining the quality of a new original component. The repaired units are also subjected to a gruelling real-life test on the DSG 6 mechatronics.

 

This means that contrary to much common thinking, TCU repair is possible, offering very significant cost saving to the garage.

 

For more information call ACtronics on 0044 1206 849920, or visit www.actronics.eu.