omeydz's Golf MK6 TSI - GTI/R20 Hybrid *DSG converted*

[dan930]

 
Goodluck tithe test drive mate

[Tfsi_Mike]

Hats off to you dude.  Maybe next year, I might be tempted with this sort of conversion.  It's crossed my mind before

[omeydz]

Thankyou! Very nervous now.. really hope it all goes well or ill cry. Lot of time, planning, favours, effort and money gone into it.

[Tfsi_Mike]

You'll get there!

[rex]

Best of luck, buddy!

[xjay1337]

Good work dude.

[omeydz]

So the eagerly awaited update:

Wiring finished and all engine bits popped together.

Coded all control modules

Engine started first time and resonator delete sounds really nice and throaty. No fault codes and shifting mechanisms all working good

Things were going too smoothly your thinking....

Well when I went to test drive I was cursing!!!

So put it into D, handbrake off and footbrake off. The revs dipped a little but wasnt going anywhere. Tried revving and no movement. Spanner flashes up on the dash. Plug in vagcom and get these fault codes

001836 - Gear 1
               P072C - 008 - Not Selectable - Intermittent

005981 - Clutch 1 Opens Unintentionally
               P175D - 000 -  - Intermittent

Clear the codes and restart the car. All seems ok.

Thought i needed to go out and dust some cobwebs. Tried reverse and worked fine, very smooth and out the workshop I go.

Put it into D - same issue as before not going anywhere in first. Then gearbox throws in 2nd and the car set of happy and smooth in 2nd.. Go down the road and back. No 3rd gear when revved more and no 1st when coming to a stop. Car was not stalling.

So car works and drives but Clutch 1 isnt grabbing 1st 3rd and presumably any other gears (5th and 7th) due to "opening unintentionally" and not engaging the gears.

Mechatronics coding is correct so Im wondering what is up with this f**king gearbox/clutch. Iv definitely fitted and wired it up right as the gears it engages work well. 

Any ideas or help much appreciated. Gearbox bought from dealers brand new and all fluids drained and replenished as gearbox sat for ages and some leaked through the caps. ??gears seized or loose clutch?!?

[JMP]

Have you performed basic settings for the dsg box? It checks the clutch bite points.

[omeydz]

Forgot to say I tried basic settings and no luck.

Found another way to do it so will try that tomorrow.

[dazza]

What box did u get 0AM??

[th3_f15t]

I have no real idea o=how the double shift gear (DSG) system works, but obviously something isn't right with the odd numbers clutch. My guesses would be:

1. Check all sensor connections and wiring, despite being plugged in, is one damaged/loose?
2. Investigate a faulty clutch due to being sat for so long
3. Hit it with a hammer.

Maybe don't do 3.

[omeydz]

Thanks guys.

Yes its 0AM 7speed dry clutch box.

I think when I was doing basic settings I didnt quite do it right and the procedure didnt go through. I have now gotten a better procedure list so hope that sorts it.

I checked the clutch assembly and it was spinning quite freely with no real resistance or wobbles so nothings seized on. ( I'd love to hit it with a hammer but want to give the basis settings another go first, if it doesnt work you can come to Carlisle with a hammer and we'll do a Jeremy Clarkson lol)

[dazza]

This is way above my DIY skills.
 
U probably already looked at these. The bottom one is very interesting for someone like me who knows nothing about how the DSG works.

http://docs.jayzone.eu/erWin/VW/Jetta%20&%20Golf%20Variant/Workshop%20Manuals/Power%20Transmission/7-speed%20dual%20clutch%20gearbox%200AM.pdf

http://www.google.es/url?sa=t&rct=j&q=&esrc=s&source=web&cd=1&ved=0CCUQFjAA&url=http%3A%2F%2Fdata.autorepairmanuals.ws%2Feb9760b153a790c74676b48736069eea&ei=zdKKVdaRI-bmyQPjra7wAQ&usg=AFQjCNHrnZJiud1omPUf8OX0owA_VLGLHg&sig2=rw7Glt6OC7P_EmqxXhA4uQ&bvm=bv.96339352,d.bGQ

[omeydz]

This is way above my DIY skills.
 
U probably already looked at these. The bottom one is very interesting for someone like me who knows nothing about how the DSG works.

http://docs.jayzone.eu/erWin/VW/Jetta%20&%20Golf%20Variant/Workshop%20Manuals/Power%20Transmission/7-speed%20dual%20clutch%20gearbox%200AM.pdf

http://www.google.es/url?sa=t&rct=j&q=&esrc=s&source=web&cd=1&ved=0CCUQFjAA&url=http%3A%2F%2Fdata.autorepairmanuals.ws%2Feb9760b153a790c74676b48736069eea&ei=zdKKVdaRI-bmyQPjra7wAQ&usg=AFQjCNHrnZJiud1omPUf8OX0owA_VLGLHg&sig2=rw7Glt6OC7P_EmqxXhA4uQ&bvm=bv.96339352,d.bGQ

Im pretty savvy with these DSGs since pondering the DSG conversion and researching it. Yep Iv already read the Technical/Education manuals and already have full access to the workshop/Elsawin manuals which were very helpful when swapping the hardware side of things over. Less helpful when it comes to the finer intricacies I am now tackling.

More I think about it the more I think I didnt do the basic settings properly. And as its a box from the dealers and not been fitted before, I presume its never been calibrated in a car and they adaptations and tolerances are wildly out methinks. I'd like to think this is true and proper basic settings will fix my issues and I can have fun with it. I cant wait... Even in 2nd and reverse those 2 gears were a pleasure to use haha 

[th3_f15t]

Normally the simplest fix is the right fix. I too have only experienced my DSG for a brief spell but I know that, despite really not wanting to loose the GTI, going to a DSG equipped Golf R was a good choice.