You get wholesale prices here and we ship worldwide where others wont. The direct shift gearbox electronically controlled dual clutch multipleshaft manual gearbox, in a transaxle design without a conventional clutch pedal, and with full automatic, or semimanual control. While doing that make sure to drive in gears 3 or 5 for approx. The directshift gearbox direktschaltgetriebe is a dualclutch gearbox designed by borgwarner and initially licenced to volkswagen group which owns the volkswagen, audi, seat, bentley, bugatti, lamborghini, and skoda brands. Audi originally used the directshift gearbox name, but now uses the name s tronic for its dcts. The engine speed window for all gears is 1200 3500 rpm for clutch calibration. Gearbox mechanicals gearbox design the 02t manual gearbox is a compact gearbox for 5speed front wheel drive. Direct shift gearbox cutaway model automotivetrainingequipment. The mechatronics control module j743 controls clutch operation and gear selection.
As you complete each shift, engage the clutch smoothly, and engage the throttle at the same time. It is the control center that shifts this manual gearbox automatically by turning on and off two separate clutch drums called the k1 and k2 clutches. It uses two clutches to change gears extremely quickly, making for imperceptible cogswaps. Direktschaltgetriebe, commonly abbreviated to dsg, is an electronically controlled dualclutch multipleshaft manual gearbox, in a transaxle design without a. Dsg, is an electronically controlled dualclutch multipleshaft manual gearbox in. Transaxle cutaway, direct shift gearbox dsg nada scientific. Credit for all the work and recommendations go to none other than this very bright and knowledgeable gentleman. Pdf modeling of a dual clutch transmission for realtime simulation. The dualclutch gearbox is a very sophisticated piece of engineering that requires maintenance. As your vehicles speed increases and you begin shifting into the higher gears, allow the engine to develop more power before each shift so the rate of acceleration increases. A dualclutch transmission dct is essentially a type of automated manual transmission in.
The direct shift gearbox is different to conventional automatic transmission as it contains two clutches controlled by a computer system. It is a twinshaft gearbox with an additional axle for reverse gear. The units need expert repair and this too can have a knockon cost. Directshift gearbox 02e eng transmission mechanics vehicles. Report dsg manual transmission transmission mechanics. Selector lever, direct shift gearbox design, mechatronics module, electrohydraulic control unit, transmission lubrication system, system overview, sensors, actuators, functional diagram, candatabuslinks, diagnostic. Volkswagen audi dsg 02e high energy friction clutch plate. Direct shift gearbox dsg check out s vw parts catalogs with products from tmi products, scat, techtonics, neuspeed, bosal exhaust, corbeau and more. Direct shift gearbox designbasic concept basically, the transmission is always engaged. The first actual dualclutch transmissions were derived from porsche inhouse development for their model 962 racing cars in the. The advantages of an automatic gearbox are, for example, a high level of comfort, above all in gear changes, as there is no interruption in tractive power. Why cvts won, directshift gearboxes lost fueleconomy fight. The contents are believed correct at the time of publication, but the current position may be checked with the clubs information department.
Each shaft is inserted into one of the discs of the coaxial clutches. Vw of america, the 02e direct shift gearbox design and function selfstudy. Share your stories, offer feedback, and connect with others on the forums. Direktschaltgetriebe, commonly abbreviated to dsg, is an electronically controlled dualclutch multipleshaft manual gearbox, in.
Directshift gearbox 02e eng transmission mechanics. Alan did an extraordinary job building a computer controlled model gearbox. Dsg gearboxes are a new development in passenger vehicle transmissions and combine the advantages of a manual type gearbox with automatic shifting, plus a double clutch, all operated by a computer and servo motors. The s tronic 02e twinclutch gearbox is also known as the direct shift gearbox dsg 02e. Ssp308 direct shift gearbox 02e vw 02e dsg gearbox dq250. The dsg direct shift gearbox is installed in audi, vw and several other european vehicles. Exploded view selector lever handle with fixed selector mechanism cover and selector lever display illumination bulb l101. The system is also expensive to make and it is a heavier than a standard gearbox. Some manufacturers have now moved on to call them the dct duel clutch transmission the dct incorporates a combination of an automatic transmission and a manual gearbox in one unit, but uses 2 clutches. Youll find your best value of price, quality parts and service here at. The first actual dual clutch transmissions derived from porsche inhouse development for 962 racing cars in the 1980s.
Dsg 02e transmission 40,000 miles maintenance service introduction this document is a reconstruction of the entire service procedure that a fellow member, wjdell, performed on my vehicles transmission on feb. Part number dsg 02e direct shift gearbox torque maximal 258 lbsft 350 nm engine dependent clutch two wet multidisc clutches gear ranges six forward gears, one reverse gear all synchronized operating mode automatic and tiptronic mode fluid volume 1. Multidomain modelling and simulation of an automated manual transmission system. This formed the framework for volkswagen to combine both transmission concepts into one completely new gearbox generation. Manual gearbox descrlption and qperatiqn operation two types of manual gearbox are fitted to the rover 800 range, type pgl which is fitted to 2. Currently, the world of transmission is dominated in europe by manual gearboxes. It is a sixspeed manual frontwheeldrive gearbox that is shifted automatically. What makes the dsg unique is that it has 2 separate gear sets operated by 2 clutches. The direct shift gearbox is basically amanual transmission designed to operatelike an automatic transmission.
May 28, 2014 why cvts won, direct shift gearboxes lost fueleconomy fight antony ingram may 28, 2014 comment now. The disadvantages of the direct shift gearbox the system requires special fluid to work and auto downshifts cut in when the accelerator is fully depressed. In place of a dry clutch, two wet clutches are used. Dsg 02e transmission 40,000 miles maintenance service. This is a cutaway of a direct shift gearbox also referred to as doubleclutch gearbox from an audivw vehicle. The dsg name applies to the vw unit and takes its name from the german name direkt schalt getriebe otherwise know a direct shift gearbox.
Blend of kevlar, ceramics, graphite, and carbon engineered to produce smooth engagements that. Directshift gearbox 02e eng free download as pdf file. Click on a productnumber to see the pricing, stock and detailed information. Both types are 5 speed constant mesh gearboxes employing. Vag ssp 851403 the 02e direct shift gearbox pdf online. Pdf dynamic and analytical analysis of the synchroniser for a. In the left screen you can drag the map around to find your product based on the technical overview. Dsg is a manual gearbox in which the gearshifts are controlled electronically. This unit uses two clutch packs, called the k1 and k2, to drive two. We design, manufacture and test our automatic transmission parts with attention to every.
The evolution of the four parameters merged in the same window on a higher scale. General information about this transmission can be found in the wikipedia entry. All change gears run in needle bearings to maximise smoothness. Direkt, commonly abbreviated to dsg, is an electronically controlled dualclutch multipleshaft gearbox in a transaxle design, with automatic clutch operation and with fully automatic or semimanual gear selection. Automatic transmission for towing this leaflet is prepared by the caravan club as part of its service to members. Dsg is a form of automatic gearbox developed by the volkswagen group, so youll see it offered across the vw, audi, seat and skoda ranges. The theoretical data is based on the direct shift gearbox 02e by. The gears on the input and output shafts are helicalcut and continously in mesh.
The 02e direct shift gearbox design and function pages 1 50. This formed the framework for volkswagen to combine both transmission. Direktschaltgetriebe, commonly abbreviated to dsg, is an electronically controlled dualclutch multipleshaft manual gearbox in a transaxle design, without a conventional clutch pedal and with fully automatic or semimanual control. In place ofa dry clutch, two wet clutches are used. Directshift gearbox part 1 v olkswagens directshift gearbox dsg 02e see figure 1 is used in the united states in some 2004topresent new beetle, new jetta and golf gti models.
Direktschaltgetriebe 1, commonly abbreviated to dsg, 2 3 is an electronically controlled dual clutch 2 multipleshaft manual gearbox, in a transaxle design without a conventional clutch pedal, 4 and with full automatic, 2 or semimanual control. Drive in tiptronic mode from stand still up to 6th gear. Twenty three years ago audi fielded its first dualclutch transmission in the 476ps sport quattro s1 rally car piloted by walter rohrl and christian geistdorfer, and since its transfer to the road in 2003 as the direct shift gearbox or dsg over 188,000 examples have been installed worldwide. A3 mk2 audi workshop manuals power transmission direct shift gearbox 02e, fourwheel drive gearbox mechanics,operation, construction,diff. Dualclutch automatic transmission directshift gearbox dsg found in various volkswagenaudi models also becoming popular with other importdomestic manufacturers the dualclutch automatic transmission or directshift gearbox dsg is in fact automatic in the sense it shifts automatically however in design and function it is nothing like a conventional automatic.
Designation dsg 02e direct shift gearbox weight approx. The volkswagen audi dsg 02e 2003on dual assembly k1 r700000 high energy friction. General information about this transmission can be found in the wikipedia. If youre reading this in north america, the vehicle sitting on your driveway probably has an.
Audi workshop manuals a3 mk2 power transmission direct. Description years qty part no twin clutch 6 speed fwd electronic control kits kit. Since ive hit around the 80,000 mile mark 82,000 to be exact, its time to do another dsg fluid change. Direct shift gearbox how is direct shift gearbox abbreviated. Direct shift gearbox design basic concept the direct shift gearbox is basically a manual transmission designed to operate like an automatic transmission.
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