VW Golf DSG issues

We were asked to carry out diagnostic’s on a 2010 VW Golf which would not always select any gears of jam in reverse.

Initial diagnostics carried out using the VW dealer tool ( Odis ) highlighted that the DSG gearbox was jamming in reverse and 6th gears.

Following guided diagnostics the test plan required the removal of the DSG Mechatronic control unit and inspection of the mechanical gearbox for signs of swarf of broken selectors.

There is a special tool required before the Mechatronic unit can be removed this is used to hold back the clutch levers so as to not damage the Mechatronic selectors.

Once the control unit was removed we carried out the inspection which showed no signs of swarf or broken selectors. If we had followed the test plan the next stage was to change the Mechatronic unit at a cost 0f £1200 + vat.

However given that the fault was related to poor selection of reverse and sixth gears we decided to try and manually select these gears.

At this point we realised that the selector lever situated at the top of the gearbox would jam up and prevent selection.

Close inspection revealed that the detent for the selector arm had worn through where it contacts the selector lever causing it to tip and jam up.

As the vehicle was low mileage with a full dealer history the customer decided to ship the whole car back to the supplying dealer for possible good will repair.

Special tool inserted before removal..
Special Tool Inserted

Mechatronic unit removed of Mechatronic unit..
Mechatronic Unit Removed

Arrow shows the selector detent jammed up..
DSG Internals

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