02E Gearbox Technology Diagnosis & Solutions – Technical Support 2012 02E TRANSMISSION FAULTS Diagnostics – Measuring value blocks - vehicles with DSG gearbox A correct diagnosis of faults on 02E DSG gearboxes can be carried out using selected measuring value blocks of gearbox electronics. Therefore, all measuring value blocks (idling when vehicle is stationary in mode P or N or D) is to be used when there is a suspicion that a fault of the transmission is involved. In MVBs, the following information may be read out: • Identification of SW and HW version of the gearbox CU (Mechatronic). • Current operating values (oil pressure values in the Mechatronic, position of the individual gear adjusters, condition of the clutches, RPM of the individual shafts, selector lever position etc.) • Continuous values recorded under operation (driving times in various driving modes, clutch temperatures under operation, driving time in all temperature modes and warning modes etc.) • Detailed ambient conditions when two last faults occurred All gearbox MVBs can be collected via the GFF test plan 02E TRANSMISSION FAULTS Complaint: Only 2nd gear can be shifted into, which in this case is also used to drive off. Reversing is not possible. Emergency program: Partial gearbox 1 switched off, partial gearbox 2 OK. Only gears 1 and 3 are still engaged (with interruption in drive). Reversing is not possible. Emergency program: Partial gearbox 2 switched off, partial gearbox 1 OK. Fault memory entry: Cause: 17160 18115 –x 18232 18237 Pressure regulating valve 2 -N216 open circuit/short to earth Fault in mechatronics unit Pressure regulating valve 3 -N217 open circuit/short to earth Pressure control valve 4 -N218, open circuit/short to earth In the mechatronics unit, electrical connections are destroyed by over-voltage. As a result, certain valves can no longer be driven. Repair note: The connections in the Mechatronic unit have been improved to resist electrical damage. In cases as above the mechatronics unit should be exchanged. 02E TRANSMISSION FAULTS Complaint: Only 2nd gear can be shifted into, which in this case is also used to drive off. Reversing is not possible. Emergency program: Partial gearbox 1 switched off, partial gearbox 2 OK. Only gears 1 and 3 are still engaged (with interruption in pull). Reversing is not possible. Emergency program: Partial gearbox 2 switched off, partial gearbox 1 OK. Fault memory entry: Cause: 18222 18227 18223 18228 Pressure regulating valve Pressure regulating valve Pressure regulating valve Pressure regulating valve 1 -N215, open circuit/short to earth 2 -N216, open circuit/short to earth 1 -N215, short to positive 2 -N216 short to positive Contamination or dirt particles in the gearbox oil can cause the pressure regulating valves to stick briefly. This sticking may be the reason for the logged fault codes. Repair note: If one of the faults named is sporadic, the first time it occurs the fault memory must be read out and deleted. Since the gearbox oil is continually cleaned by the pressure oil filter, it is highly probable that the fault will not occur again. If one of these faults reoccurs, the mechatronics unit must be exchanged. 02E TRANSMISSION FAULTS Complaint: Inverted gear display in instrument cluster. Fault memory entry: 17115 17116 17117 17118 17119 17113 1. gear wrong transmission ratio 2. gear wrong transmission ratio 3. gear wrong transmission ratio 4. gear wrong transmission ratio 5. gear wrong transmission ratio 6. gear wrong transmission ratio 17106 Gearbox output speed sender 1 -G195, no signal 18201 Gearbox output speed sender 2 -G195, no signal 19143-8 Fall-off of rpm on input shaft 1 or input shaft 2 detected. Cause: RPM sensor G195 and G196 defective, Hall sensor electrical damage (sporadic short) Repair note: If one of the faults logged is sporadic, the first time it occurs the fault memory must be read out and deleted. It is highly probable that the fault will not reoccur. If one of these faults reoccurs the mechatronics unit must be exchanged. 02E TRANSMISSION FAULTS Complaint: Only 2nd gear can be shifted into, which in this case is also used to drive off. Reversing is not possible. Emergency program: Partial gearbox 1 switched off, partial gearbox 2 OK. Only gears 1 and 3 are still engaged (with interruption in pull). Reversing is not possible. Emergency program: Partial gearbox 2 switched off, partial gearbox 1 OK. Fault memory entry: Cause: 17130 17160 18232 18237 19155 19164 Pressure control valve 1 -N215, open circuit/short to earth Pressure regulating valve 2 -N216, open circuit/short to earth Pressure regulating valve 3 -N217, open circuit/short to earth Pressure regulating valve 4 -N218, open circuit/short to earth Pressure regulating valve 5 -N233, open circuit/short to earth Pressure regulating valve 6 -N371, open circuit/short to earth. Contact problems in the power supply to the valves listed above. Repair note: If one of the faults named is sporadic, the first time it occurs the fault memory must be read out and deleted. Take a test drive. The gearbox oil temperature should exceed 90 °C. If the fault reoccurs, the mechatronics unit must be exchanged. 02E TRANSMISSION FAULTS Complaint: Judder, erratic gear shifting Fault memory entry: 17252 - Transmission pressure adaptation at impact upper limit exceeded Cause: extreme levels of enhancement chip tuning Repair note: check vehicle if possible for TD1 in vehicle data online (PR codes) info. Please reference Desktop bulletin regarding TD1 information. 02E TRANSMISSION FAULTS Complaint: Vehicle has no propulsion (drive) Fault memory entry: 18203 -x 17106 18201 Signal for road speed, open circuit Gearbox output speed sender 1 -G195, no signal Gearbox output speed sender 2 -G196, no signal Sender arm with G195 and G196 Cause: 18203 -x, Failure of both gearbox output rpm from sensors G195 and G196. 17106,18201 Diagnosis too sensitive, plausibility check of output rpm 1 or output rpm 2 to average front CAN drive. wheel rpm. Possible fault in brake electronics. Both entries often occur simultaneously Repair note: 18203 -x 17106 and/or 18201 1. Delete fault memory, then take a test drive. MWB 8 displays rpm. 2. If the 18203-x reoccurs: exchange the mechatronics unit. check brake electronics CAN signals. Are the brake electronics on the CAN bus? Are faults in the brake electronics fault memory relating to the wheel rpm sensors? Delete all faults, then take a test drive. If one of the faults 17106 or 18201 reoccurs, the mechatronics unit must be exchanged. 02E TRANSMISSION FAULTS Complaint: Sporadically delayed application of power, then driving off with juddering Fault memory entry: Cause: 17100 Gearbox input speed sender -G182; implausible signal 18148 Clutch temperature monitoring Poor sensor connection or signal interference. Repair note: Check whether the plug of the gearbox input rpm sender is correctly seated. If the plug is correctly seated, it can be assumed that the sender or the cables are defective. If the area of the sender proves to be the cause of complaint, the mechatronics unit does not need to be exchanged. If the error occurs although no fault in sensor -G182 can be determined, exchange the mechatronics unit. 02E TRANSMISSION FAULTS Complaint: Jerking on pull away when vehicle is warm. In most cases, no fault is stored in the fault memory of the Mechatronic unit. Cause: An internal fault of the Mechatronic control unit. Wear on clutch control valve mountings means the curve for controlling the pulling away clutch can’t be maintained. Repair note: Check the date of Mechatronic production. Material changes for mounting of the clutch control valves have been made. Checking procedure: Self diagnosis 02 – Gearbox, 011 – Measuring value block - Channel 54 H07A0001 - J21N0560 H = year 2007; 07 = calendar week , J = year 2008; 21 = calendar week Measure: If you find out that the production date lies in the above range (H07 – J21), replace the Mechatronic. After the replacement, carry out the basic setting and adaption test drive. 02E TRANSMISSION FAULTS Complaint: Communication faults Fault memory entry: 18262 18274 Drive train data bus defective Drive train data bus missing messages 18256 18258 18260 Please read out engine control unit fault memory, fault entry only. Drive train data bus missing messages from engine control unit Drive train data bus, implausible message from engine control unit 18255 18259 18261 Please read out ABS control unit fault memory, fault entry only. Drive train data bus missing message from ABS control unit, fault entry only. Drive train data bus, implausible message from ABS control unit, fault entry only. 18250 18270 18082 Please read out instrument panel fault memory, fault entry only. Drive train data bus missing message from instrument panel, fault entry only. Drive train data bus, implausible message from instrument panel, fault entry only. 18036 18273 Drive train data bus, missing message from steering angle sender, fault entry only. Drive train data bus, missing message from central electronics unit, fault entry only. Drive train data bus, missing messages from steering column electronics -J527, fault entry only. 18275 Cause: Lies in communication with control units whose information is need by the gearbox control unit for proper operation. Repair note: Don’t just consider the gearbox for the fault. Please look at the ECU listed in the fault description. 02E TRANSMISSION FAULTS Complaint of judder: This test can be used to determine if a complaint of judder on pull away is caused but a clutch issue. By allowing the gearbox to pull away in second gear rather than first gear you may find the judder on pull away is reduced or removed. If this is the case then the judder is caused by K1 clutch and not the Mechatronic control. Test: • Insert the gear “D” and then switch the selector lever from D to R three times. • You should then be able to start in the second gear (dash will only display ‘2’ once the vehicle is moving). • At the start pay attention that the engine speed is a little increased. • Pull away slowly Repair: If the complaint is now removed, you are looking at clutch creep and the multi-clutch should be considered for replacement. 02E TRANSMISSION FAULTS Complaint: Clutch judder/delay in drive Cause: Clutch, defective centrifugal oil compensator Test: • • • • Vehicle is at rest on the level, brakes may not be actuated. Engage driving position N. Increase engine rpm to upper rpm limit, maintain this for 5 seconds. Repeat the cycle 20 to 30 times to ensure there is no defect. Result: How are defective double clutches recognised? If the vehicle starts to creep backwards from about 4000 rpm, the test must be terminated. This avoids further damage to the 3rd gear synchronisation. Repair: Replace the clutch 02E TRANSMISSION FAULTS Complaint: Cause: When rolling forwards from a standstill, a juddering can be felt in the drivetrain (creep juddering). Creep juddering results from a non-uniform torque < 1Nm which results from different thicknesses in the material of the clutch plates. Repair work: Action: Observe mandatory notification. Replace double clutch. Optimisation of production at supplier. The clutch plates are "matched" by the manufacturer, i.e. they are repeatedly turned and fitted until the lowest possible non-uniform torque exists. The clutch plates are then sent paired in the clutch cage as original parts. When fitting an original clutch, care should therefore be taken that the clutch plates do not fall out of the clutch cage. The fitting position of the clutch plates is not marked. If a clutch plate assembly has separated, correct reassembly in the workshop can not be guaranteed. There is a danger that the new original parts clutch judders when driving off. Creep juddering. Mechatronics unit, fault analysis 02E Transmission Faults Complaint: Noises, juddering, gearbox does not shift smoothly, no or delay in drive. Fault memory entry: Cause: No fault memory entry present. The causes of complaints can be found in many different areas of the vehicle such as the engine or the suspension. Analysis of mechatronics units that have been exchanged, and experience, show that changing the mechatronics without a fault memory entry being present generally has no influence on the complaint. Repair note: If no fault memory entry exists, and uncertain on repair. If in doubt contact the Technical Support via DISS Technical enquiry. Please include an accurate description (refer to the separate attachment). of the complaint and all transmission MVB in P/N and engine running via the GFF test plan.
