DSG Gearbox

Direct Shift Gearbox

DSG

P Phelan

Introduction

Currently the world of transmission is dominated in Europe by manual
gearboxes and in the USA and Japan by automatic gearboxes

The advantages of a manual gearbox are

●
●

The advantages of an automatic gearbox are:

●

Introducion

Currently the world of transmission is dominated in Europe by manual
gearboxes and in the USA and Japan by automatic gearboxes

The advantages of a manual gearbox are

●High degree of efficiency

●Robust and sporty characteristic

The advantages of an automatic gearbox are:

●A high level of comfort, above all in gear changes , no interruption in
tractive power This formed the framework for Volkswagen to combine
both transmission concepts into the Direct shift gearbox

Mechatronics

Multi-plate clutch

Thanks to the double multi plate clutch design
it is able to meet the high demands from the
driver

Set Google Quiz DSG

after film played

Basic Principle

The direct shift gearbox comprises in essence of two transmission units that
are independent of each other.

Each transmission is constructed in the same way as a manual gearbox.
Allocated to each transmission is a multi-plate clutch.

Both multi-plate clutches are of the wet type and work in DSG oil. They are
regulated, opened and closed by the mechatronics system depending on
the gear to be selected.

1st,. 3rd and 5th are selected via multi-plate clutch K1.

2nd, 4th and 6th are selected via multi-plate clutch K2

The Direct Shift Gearbox is distinguished by:

Six forward gears (DSG O2E)

Normal driving program ‘D’

Sports program ‘S’ as well as Tiptronic (steering wheel paddles optional)

Mechatronics, electronic and electro-hydraulic control unit form one unit and
are housed in the gearbox

Hill Hold function, if the vehicle is stationary , with light brake application, the
clutch pressure is increased and the vehicle is held in position

Creep regulation allows creeping of vehicle, for example parking without
acceleration

Emergency mode, vehicle can be drive in 1st and third or just 2nd gear

DATA

DSG 02E (DSG)

Weight 94 kg

Torque 350 nm

Clutch Two multi-layer wet plate clutches

Gear stages Six forward, one reverse (all syncronised)

Operating mode Automatic & Tiptronic
Oil Volume 7.2 ltr DSG Oil G052 182

The selector lever is actuated in the vehicle and offers direct shift and the
option of tiptronic

P =

R =

N =

D =

S =

+And -

The selector lever is actuated in the vehicle and offers direct shift and the
option of tiptronic

P = Park

R = Reverse Gear

N = Neutral

D = Drive

S = Sport

+And - The tiptronic functions can be used with the selector in the right
gate and the steering wheel paddles where fitted

Design of selector lever

Selector lever sensors control unit J587

Hall sensors in the gear selector lever mounting

detect the position of the selector lever and make

the positions available to the mechatronics via

the CAN bus .

F319

If the selector lever is in the "P" position, selector

lever locked in position "P" switch sends a signal

to the steering column electronics control unit

Hall effect sensors

Basic Principle

The DSG gearbox comprises of two transmission units that are
independent of each other.

They each are allocated to a multi-plate clutch.

Both multi-plate clutches are the wet type and work in DSG oil.

They are regulated, opened and closed by the mechatronics
system, depending upon the gear to be selected.

1st, 3rd and 5th and reverse are selected by multi-plate
clutch K1

2nd 4th and 6th gear are selected by multi-plate clutch K2

One transmission unit is always in gear and the other
transmission unit has the next gear selected in
preparation but with the clutch still in the open position.

Every gear is allocated a conventional manual gearbox
synchronistion and selector element.

DSG Clutch

The torque input is transmitted from the crankshaft to the dual mass
flywheel.

The splines of the dual mass flywheel on the input hub of the double clutch
transmit the torque to the drive plate of the multiplate clutch.

Mechatronics

The mechatronics are housed in the gearbox, surrounded by DSG oil. They
comprise of an electronic unit and electro-hydraulic control unit.

The mechatronics form the central control unit in the
Gearbox. All sensors and all signals from other control units
Come together at this point and all actions are initiated
And monitored from here.

Housed in this compact unit are twelve sensors, only two
Are located outside of the mechatronics system.
By hydraulic means it controls or regulates eight gear actuators
Via six pressure modulation valves and it also controls the pressure
And flow of cooling oil from both clutches.

The mechatronics control unit learns (adapts) the position of the clutches,
the positions of the gear actuators when a gear is engaged and the main
pressure

7 DSH Oil & Filter Change

Any questions ?