vw dsg hydraulic pump play protection supplier

Hi - I have been to my mechanic who has recorded a fault on my 2013 polo GTI. It reads: hydraulic pump - play protection. Is this likely to be a fault in the main transmission or the mechatronics unit??

I have to take it to VW for diagnostics before they"ll give me a straight answer. At $195 per hour of course. After which they"ll just tell me it was the same fault code my mechanic recorded I"m sure of it. They did tell me there was no outstanding recalls on the car, so I"ll probably have to pay for it. There"s a fair bit of difference in price depending on which part is causing the issue, $7300 for a transmission vs $2300 for a mechatronics unit. Can anyone offer any advice? thanks!

This DSG 7 control unit is a very common failure for vehicles built between 2003 – 2016 fitted with the DQ200 Direct Shift Gearbox (DSG). The most common reported symptom is a complete loss of drive due to not being able to select any gears, this will cause the EPC light to remain illuminated and the gear symbols will continually flash on the instrument panel. Often the main 30-amp fuse will be blown, if you try to replace the fuse it will blow again while the DSG control unit remains connected.

If you attempt to read the fault codes stored in the gearbox system, then you may also notice the gearbox system fails to communicate with your diagnostic scanner, preventing you from reading any fault codes. However, if you are able to communicate with the DSG gearbox system, then you may have the following fault codes stored:

We are able to remanufacture (rebuild) your own DSG unit and supply an unlimited mileage lifetime warranty as standard. When we rebuild your own unit, we use higher rated than standard components and ‘engineer out’ the original design flaw that caused your unit to fail in the first place, giving you the peace of mind that your unit will not fail again. If we rebuild your own unit then it will cost a small fraction of the cost of a new unit, and you will not need to program the unit back onto your car – simply refit, replace the oil and away you go.

This is a complete re-engineered solution for the DSG-7 family of mechatronics units, all failing components are replaced with our own re-engineered versions, designed from scratch to outperform the original OEM parts. Employing our in-house designed reinforced stainless-steel pressure build-up controls, polymer clutch actuation protection and control unit revision, complete HIL simulation redesign to ensure all shift actuators are meeting and exceeding original OEM specifications in real-world conditions.

We fully test every Mechatronics unit before (first line test) and after (end of line test) the rebuild, using our HIL (Hardware In-the-Loop) DSG-7 Gearbox rig, this allows us to test your Mechatronics unit under real-world load conditions. This ensures that each rebuilt unit meets and exceeds OEM specifications. All common failing components are replaced with versions that are higher rated than standard, so you can be assured that once your unit has been rebuilt it will perform as good as, if not better than a brand-new unit from the manufacturer.

The VW/Audi group DSG7 DQ200 mechatronic will typically cause gear change problems on the vehicle. However, it’s not always the mechatronic unit that causes drivability problems.

Package the DSG7 transmission control unit inside a sturdy box with plenty of packaging material (make sure you include your confirmation email in the box).

Once received we will test, rebuild and return your DSG7 transmission unit with an unlimited mileage lifetime warranty. (if your unit turns out not to be faulty then we will refund your payment less a small testing fee and return shipping)

Package the DSG7 transmission control unit inside a sturdy box with plenty of packaging material (make sure you include your confirmation email in the box).

Once received, we will test your DSG7 transmission unit and call you to advise on the outcome of testing, if your unit is faulty and you choose to go ahead with the rebuild then we will take payment over the phone using a debit/credit card.

The dry clutch 7 speed DSG gearbox suffers from several common faults. This guide details the issues that affect the Audi S Tronic, VW, Seat and Skoda, DSG 7 speed models which can be repaired and even upgraded with modified parts.

Please note, this guide is for the DSG 7 Dry Clutch systems found on models with an engine capacity of under 2000cc. This guide does not relate to the OB5/DL501 DSG 7 gear wet clutch system equipped on the larger Audi models.

This version of the DSG gearbox is often referred to under a few different names including, 0AM, 0CW, 7DSG and DQ200. You will find this version of the transmission on the smaller engine models in the Audi, Seat, Skoda and VW range.

DSG gearbox problems are not uncommon, and unfortunately this model of DSG gearbox suffers from its own set of various faults, luckily all of which have viable repair solutions.

This issue can be rectified by Eco Torque, by reconditioning the mechatronic unit and upgrading the valve body with the new superseded design which VW/Audi addressed and which cures this issue.

The IC motor and high-pressure pump are common components for failing on the DCT DSG mechatronic unit. Pressure leaks can cause the high-pressure pump to overwork and burn out. The failure of these two components are however usually secondary issues, which are misdiagnosed as the primary suspects.

Solenoid failure is very common on the VW DSG, Audi S-Tronic 7 Speed Mechatronic units. This is one of the most common issues we see at Eco Torque and failures can be caused by contamination in the oil from component breakdown, as well as internal electrical faults.

One particular issue our customers come to us with is that their vehicle doesn"t go into reverse or they cannot select 6th gear. It is also something we check when removing and replacing mechatronic units, as the selector is partially visible. If you own a DSG 7 speed vehicle older than 2018 then this fault is a case of "when" not "if".

This fault is exclusively found on the 0AM 7 Speed DSG DQ200 gearbox models. The replacement of this component in the unit will greatly improve the DSG gearbox reliability.

The DSG clutches on the 7 speed gearbox are made of two individual friction material design discs, housed in one unit with two operating diaphragms. As they are constructed in a similar way and of the same material as your standard manual transmission clutch, they also suffer from the same wear and tear issues and failures.

DSG clutch wear in the 7 speed gearbox result in clutch judder when accelerating from standstill or when changing gears. It can also produce an over-revving effect as the DSG clutches slip and struggles to gain grip to transmit the power from the engine through the gearbox. These symptoms are usually accompanied by a fault code on the system relating to the clutch (clutch 1/2 tolerance limit reached).

In more severe cases the engagement of the DSG clutch pack can result in a heavy/violent bang, which can stall the engine. It is highly recommended to change the clutch before this point as it can cause additional damage to the dual mass flywheel.

It is vitally important that the DSG clutches are installed by an experienced mechanic and shimmed correctly using the specialist tools required. We have numerous customers come to us believing they have issues with their mechatronic unit, for us to discover their DSG clutch has been installed incorrectly, which drastically reduces it"s lifespan.

Eco Torque offer an initial electronic diagnostic service with our main dealer equivalent machine. This shows us live data from the gearbox as well as a report for the customer to see the fault codes within the DSG unit. This essential first step is £90 including VAT and takes around 1 hour to complete.

The dry clutch 7 speed DSG gearbox suffers from several mechatronic faults. This manual details the issues that affect the Audi S Tronic, VW, Seat and Skoda, DSG 7 speed models which can be repaired and even upgraded with modified parts. This relates to DSG 7 Dry Clutch systems found on models with an engine capacity of under 2000cc with engine torque to 250Nm. This manual does not relate to the 0B5/DL501, DQ500, DQ381 and DQ382 DSG 7 gear wet clutch system equipped on the larger Audi models.

This version of the DSG gearbox is often referred to under a few different names including, 0AM, 0CW, 7DSG and DQ200. You can find this version of the transmission on the smaller engine models in the Audi, Seat, Skoda and VW vehicles.

Our unique repair kit allows you to completely restore a broken valve body.The hydraulic accumulator is attached to the damaged housing and completely restores the mechatronics hydraulic system. In most cases, the mechatronics module can be removed in a garage and the automatic transmission can be repaired right on the spot. If such a possibility is excluded, our solution is still simpler and more reliable than replacing the valve body plate, which requires a complete disassembly of the mechatronics.

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Some garages and main dealers write-ff an entire DSG7 gearbox, when only the mechatronics unit is faulty. Rob Marshall partners with ACtronics, to discover how garages separate and reunite the two components safely, saving your customer money and ensuring a boost to your turnover and reputation.

Volkswagen Group’s Direct Shift Gearbox (DSG) is an automated manual twin- clutch design, introduced to offer a more efficient and faster-changing alternative to the traditional epicyclical geared/torque converter automatic types of transmission. The Audi TT 3.2-litre V6 was the first model sold in the UK to feature the technology. The 6-speed ‘wet clutch’ unit had its clutch packs lubricated by special oil that requires routine replacement.

The DSG7 was a development that not only featured an extra ratio but also offered reduced weight and higher efficiency. It debuted in 2008. A major difference was the use of dry clutch packs, located not within the gearbox casing but the bellhousing. For the sake of simplicity, this article focusses on the transverse 7-speed unit that the trade motor electronics remanufacturing specialist, ACtronics, reports as one of the most common units that its engineers encounter. We are not covering the longitudinal version, such as Audi’s S-tronic, although there are similarities.

Like its 6-speed predecessor, the gearbox’s clutch and gear shift forks are controlled by a separate ‘mechatronics’ unit that is bolted to the side of the gearbox. It contains the Transmission Control Module (TCM – basically, the ECU) to control actuation of both clutch levers and the gear selectors. Unlike its wet-clutch 6-speed predecessor, the DSG7 contains its own oil supply, separate from that of the gearbox, and includes solenoid valves, slave cylinders, a pump and a high- pressure accumulator to maintain the required 40-60BAR.

The mechatronics TCM receives, transmits and reacts upon information that it receives not only from within the gearbox (such as internal shaft speed, gear position and oil temperature) but also externally from the car’s various other systems. Electrical solenoids that activate the hydraulic actuators then act upon a pair of clutch release levers and four gear shift selectors.

Loss of drive is the chief complaint, due to an inability to select any gears. You may also notice flashing gear symbols displayed on the dashboard, which means diagnostic interrogation is needed to access a fault code. Should your equipment not communicate with the TCM, check the 30 Amps power supply fuse. Should a replacement blow instantly, the TCM has likely failed and retrieving a code is impossible. In any case, the mechatronics will require removal but, before you do so, perform your usual checks before jumping to a snap diagnosis, including verifying wiring loom condition, the battery’s state of health and alternator output.

Sulphur that is present within the gearbox oil manages to degrade the mechatronics body and penetrate the TCM, causing electrical shorts. Before a total loss of drive occurs, early symptoms include shuddering and even a loss of engine power. Yet, check that the many Volkswagen Group software updates have been applied. Other issues include the internal pump failing, causing a low-pressure situation and no drive – fluid leaks from the mechatronics breather (See Step 1) and a fault code relating to ‘Pump Play Protection’ tend to be the leading symptoms. Most main dealers would recommend replacing the entire gearbox and mechatronics unit together at a relatively huge cost. Thankfully, aftermarket garages have a cost-effective alternative to offer.

pins (See Step 6) and locate the collars on the hydraulic actuators (pictured in Step 9) within those of the four gear selectors, one of which is pictured. This ensures that the mechatronics can operate the gear selectors with no possibility of them becoming detached.

ACtronics advises that you can check online, by logging onto www.actronics.co.uk and click on ‘free search’. Enter ‘DSG’ and follow the menus, prior to logging-in to complete the registration, which includes access to pricing information. Print off the Remanufacture Order Form afterwards.