DSG-7 clutch replacement. Transmission DSG-7

The Robotic transmission DSG-7 was released in 2006. The system is a robotic seven-speed mechanical transmission. This transmission is characterized by the presence of two dry clutches and two input shaft. The purpose of this box is the combination of the manual transmission efficiency and comfort of a classic automatic, tat existed at that time "the robot" with one clutch not quite satisfy the constantly growing requirements. Here the transfer switch without breaking the flow of torque, that is, without installing it into neutral. This is the main advantage of the automatic transmission. This box set is for cars of concern VAG – “Audi”, «Volkswagen», «Skoda» and others. Because it is based on a manual transmission, it is periodically necessary to change the clutch. Let's see what is on DSG-7 clutch replacement you need and you can carry out the replacement process with their hands.

Feature “robot" DSG

The Peculiarity of this box is that, in addition to the two clutches, it has also two amount of oil. The first control unit serves DSG-7, which controls the operation of the mechanism. The second is designed for the mechanical reducer. If the manual gearbox the clutch is clamped design springs, and when you press on the pedal it is dissolved and torque on the driving wheels is not transmitted, everything is exactly the opposite. While the mechatronics for the DSG-7 will not submit a corresponding signal, the clutch connected to the flywheel and can rotate freely. Once the signal is filed, a special piston will start to interact with the plug that will clamp the disc. The coupling piece is pressed only if the system has no oil leaks.

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The Clutch in DSG-7 – this is a separate sealed and not repair the unit. If you need to replace the mechanism comes already assembled with adjusted and ready for installation discs.

About installing clutch

Robotic double clutch DSG-7 from VAG and LUK in the automotive market have become virtually synonymous with innovative solutions, but not only them. As you know, around these boxes was a lot of noise, which is associated with some erroneous design solutions. The company's VAG has taken more than six years to this transmission became to work normally. Now the transmission is really different with a stable job. And the number of people accessing services with faults the clutch, dropped sharply. The Reason for frequent failures of the box are not only the mistakes of engineers. Many drivers simply do not know how to handle the new dual-clutch transmission. But this is a fairly complex site that has certain rules of operation. The price of a full replacement will be 100-250 thousand roubles. Repair DSG-7 will be cheaper. This figure is significantly hits the pocket, so many motorists who know a little about car repair, try to change the clutch yourself. And though this transmission is a complicated engineering solution, it is based on a conventional manual transmission, albeit modernized. So, DSG-7 clutch replacement with your own hands is possible.

Self-replacement: what do we need?

To replace many resolved after the car has left its warranty period and repair at the official dealer for free became impossible. Indeed, such serious warranty work will cost dearly.

If the owner still decided to try to make their own replacement after the diagnosis, he should understand that this procedure is not free, though much cheaper. The first step is to buy a LUK kit. This is a dual-clutch DSG-7. The kit price is on average 25 thousand rubles.

Tool Kit

Next, you should purchase a set of special tools directly to replace the clutch on boxes of this type. The cost is much higher and amounts to about 90 thousand rubles. This is a pretty serious amount. If the price doesn't stop using this set of tools will be possible to perform a full complex of works even without instructions, the Internet and technical regulations. The kit from LUK the disk, which is a detailed manual for performing the operation. The set will serve its owner for a long time, although the cost remains high and unjustified. Installation kit tools SAC will be much cheaper, although it has less tools. But the price – 15 thousand rubles. Some craftsmen can do without special tools. Just need to find the right box for the keys. But this approach is not welcome, as the repair for the DSG-7 is serious business.

List of works to replace the clutch

If the price of the instrument does not stop and all you need is already purchased, you can begin to work. The whole process divided into several stages. First, carry out the dismantling of the checkpoint. This will help the hanging mechanism. It can be used to fix the system before you start to Unscrew its fasteners. Then it is recommended to check the oil level. If you see streaks, add oil to the gearbox DSG-7 or replace it. Next, using tools from the kit, remove the clutch mechanism. In the process of dismantling must be aware that the adjusting ring can be both above and under the clutch release bearing. It depends on which model of clutch.

Then you must clean and thoroughly wipe down the output shaft. For cleaning better to use a means that does not contain solvents or other aggressive substances. Grease is better left on the input shaft splines. Then check the oil seal for the presence of streaks.

The Selection of adjusting rings

The New parts are installed in reverse order. On release bearing set the most thin ring. Its size is 2.8 mm. If there are difficulties in the process of pulling the installation of calibers, you need to install the second ring in width. Rings are selected as long as the element will not easily pass through the ring. If everything is correct, calibre will move by 0.1 mm. the Selection of the adjustment ring is relative to the individual tolerance of clutch. These tolerances can be found on the clutch side of the power unit. Depending on the tolerances of the mark – to take away or add to the size of the tolerance on the thickness of the ring. For example, the nominal thickness of the washers & ndash; 2.0 mm. the Tolerance is +0.2 mm. Then the final size of the washer will be 2.2 mm.

Installation

The Installation begins with the most delicate ring. It puts on small pressure bearing of the second clutch. Action on the selection of rings repeat it here. Correctness of installation check a special caliber. The final selection process of the ring shall take place in accordance with the tolerances. But now consider the second parameter. The Shaft is oiled. You should be careful not to coat the disks. Otherwise, the clutch will constantly slip. Torque in this situation is not completely or smoothly. Then measure the distance between the upper edge of the bearing ring and smooth shaft surface. This distance should not be more than 8 mm. Further opressovkoy shaft. The crimping process can be stopped when the retaining ring is visible in one of the holes in the sleeve. At the end of the stopper is set to the narrow part up.

Adaptable

That's all for the mechanical parts. But for DSG-7 clutch replacement – it's not only physical work. You need time to adapt the new mechanism. This process can be done at home using special software and diagnostic cable. And only after that to start full operation.

So we figured out how is to DSG-7 clutch replacement with your own hands.