DSG died how to deal with the Dealer

[nomnomguy970]

As a 2010 DSG owner i knew this day would come.[=(] "Gearbox Malfunction (limited functionality)" I limped to the dealer which was thankfully only a few miles away. After a week of driving a Allroad courtesy car, my service adviser emailed me and told me he needed to replace a "Circuit Board" (im assuming Mechatronics) and it would cost $2150.00. I have read on this fourm that many people have gotten audi to either split the cost or completely cover the cost of the repair. I tend to avoid confrontation and don't really know how to go about asking them to pay for it. (I admit its my greatest failing) I do have a few things on my side. My car is 100% stock and a few weeks prior I got the DSG fluid and filter changed by another audi dealer a couple miles away.

[s4buckeye]

ask them nicely and explain to them that Audi has paid for others - preferably you can find others in the Bay Area that had it done and maybe someone did at the current dealer or the last one you were at. be nice, be reasonable and be persistent and see if others on AZ can give you their specifics as to when, where and how much if they had it paid for.


if that does not work, then call AoA as a next step.


if those two steps fail, then embrace the confrontation.

[namvar]

As a 2010 DSG owner i knew this day would come.[=(] "Gearbox Malfunction (limited functionality)" I limped to the dealer which was thankfully only a few miles away. After a week of driving a Allroad courtesy car, my service adviser emailed me and told me he needed to replace a "Circuit Board" (im assuming Mechatronics) and it would cost $2150.00. I have read on this fourm that many people have gotten audi to either split the cost or completely cover the cost of the repair. I tend to avoid confrontation and don't really know how to go about asking them to pay for it. (I admit its my greatest failing) I do have a few things on my side. My car is 100% stock and a few weeks prior I got the DSG fluid and filter changed by another audi dealer a couple miles away.

Call my service advisor at Audi Concord. His name is Mike Forney. Tell him I referred you from the forum. He is extremely professional and will do everything he can to help you. No promises though.

[Michaelds4]

When installing my rs4 grill and wire mesh behind I some how damaged my radiator took it to livermore audi and they replaced it for me for free even though they weren't liable. They have always been cool with me might want to give them a call as they might give you the same service...good luck

[Hansel]

I just paid $1300 for my second unit. Only reason they paid 1/2 is the fact they are blaming it on the tune.

[bronz]

I just paid $1300 for my second unit. Only reason they paid 1/2 is the fact they are blaming it on the tune.

Which dealer did you work with?

[cookinsolo]

my 2010 is at the dealer right now, the tech was saying I'm getting the gearbox malfunction error because the circuit board is slowly detaching away from the mechatronic unit, so instead of replacing the whole unit they replace the circuit board using a repair kit
thankfully i still have CPO so its covered, my mechatronic unit was already replaced long time ago.

[Deckdout2]

There's gotta be a how-to on replacing this yourself, or if not has anybody done this themselves? I would have to probably pull teeth to get them to pay for anything on my car as modded out as it is, and I'd rather do it myself if I can.

Does anyone have a breakdown on parts and labor cost of replacing this?

[cookinsolo]

There's gotta be a how-to on replacing this yourself, or if not has anybody done this themselves? I would have to probably pull teeth to get them to pay for anything on my car as modded out as it is, and I'd rather do it myself if I can.

Does anyone have a breakdown on parts and labor cost of replacing this?

my car should be done by 4pm EST today, when i pick it up ill get a break down and update u

[Deckdout2]

my car should be done by 4pm EST today, when i pick it up ill get a break down and update u

That's great, thank you! I'm dreading the day that I'll have to do this myself. Hopefully, it's not anytime soon.

[skiptowncat]

There's gotta be a how-to on replacing this yourself, or if not has anybody done this themselves? I would have to probably pull teeth to get them to pay for anything on my car as modded out as it is, and I'd rather do it myself if I can.

Does anyone have a breakdown on parts and labor cost of replacing this?

I'm pretty sure you have to take the gearbox off, not a diy job really.

[Deckdout2]

I'm pretty sure you have to take the gearbox off, not a diy job really.

I've fully built a motor and changed the final drive in my previous car's 6-speed manual. No it's not for the daunting, but yes it can be done outside of a dealership. [:)]

We need more gear heads in this platform.

[6spdg37s]

reading this thread makes me really happy that I ordered a 6mt lol

[DGVR6]

Isn't the mech unit similar to a valve body?

If so there shouldn't be a need to remove the whole gearbox.. There should be a cover over it next to the gearbox...

If it isn't a tight squeeze, you can drain the fluid, remove cover, disconnect the mech and then replace with new, Fill fluid.

[DGVR6]

Matter fact here is a video that I just found.
Definitely no need to remove gearbox.

http://youtu.be/trhfvm5aJAY
http://www.jimellisaudiparts.com/images/parts/Audi/fullsize/291325800.jpg

[vacsimile]

Matter fact here is a video that I just found.
Definitely no need to remove gearbox.
video=youtube_share;trhfvm5aJAY]http://youtu.be/trhfvm5aJAY[/video]

That's a totally different car with a transverse engine, like a TT, A3 or a Jetta (and other cars along those lines).

There are two bulletins for this transmission that seem to be getting confused by SA's. The first is to replace a circuit board on the mech unit, and it just requires the mech unit to be removed. Transmission stays in the car. It only takes a couple of hours and parts are less than $400, so the whole job should cost under $1000.

The other bulletin is for replacing the input speed sensor module (which has a circuit board), but that requires the transmission to be removed and about 90% of the gearbox has to be taken out of the case. The transmission has to be mounted vertically and the entire shaft/gear assembly for both transmissions is removed with a cherry picker. The thing is really heavy and it's surrounded by delicate plastic guides and tubes. It's pretty cool actually, reminds me of those shows where they have to disarm a nuclear warhead or something, lol. Anyway, that job takes 20+ hours and takes a huge list of parts. Since the OP said they quoted him $2150 I imagine it is the latter job. $2150 seems kind of low, actually.

Replacing the circuit board on the mech unit would be easy to do at home. The mech unit itself is a lot heavier than other valve bodies so get some help or use a jack to support it when removing/installing it.

The sensor module replacement would be pretty tough to do at home. You'll need a few of the special tools for this transmission and lots of patience. Just getting the transmission out is tricky by itself.

[cookinsolo]

That's a totally different car with a transverse engine, like a TT, A3 or a Jetta (and other cars along those lines).

There are two bulletins for this transmission that seem to be getting confused by SA's. The first is to replace a circuit board on the mech unit, and it just requires the mech unit to be removed. Transmission stays in the car. It only takes a couple of hours and parts are less than $400, so the whole job should cost under $1000.

The other bulletin is for replacing the input speed sensor module (which has a circuit board), but that requires the transmission to be removed and about 90% of the gearbox has to be taken out of the case. The transmission has to be mounted vertically and the entire shaft/gear assembly for both transmissions is removed with a cherry picker. The thing is really heavy and it's surrounded by delicate plastic guides and tubes. It's pretty cool actually, reminds me of those shows where they have to disarm a nuclear warhead or something, lol. Anyway, that job takes 20+ hours and takes a huge list of parts. Since the OP said they quoted him $2150 I imagine it is the latter job. $2150 seems kind of low, actually.

The sensor module replacement would be pretty tough to do at home. You'll need a few of the special tools for this transmission and lots of patience. Just getting the transmission out is tricky by itself.


yea this is very accurate. i had my circuit board replaced today, it was coming apart apparently, and they did say there was a bulletin for it.

[DGVR6]

That's a totally different car with a transverse engine, like a TT, A3 or a Jetta (and other cars along those lines).

There are two bulletins for this transmission that seem to be getting confused by SA's. The first is to replace a circuit board on the mech unit, and it just requires the mech unit to be removed. Transmission stays in the car. It only takes a couple of hours and parts are less than $400, so the whole job should cost under $1000.

The other bulletin is for replacing the input speed sensor module (which has a circuit board), but that requires the transmission to be removed and about 90% of the gearbox has to be taken out of the case. The transmission has to be mounted vertically and the entire shaft/gear assembly for both transmissions is removed with a cherry picker. The thing is really heavy and it's surrounded by delicate plastic guides and tubes. It's pretty cool actually, reminds me of those shows where they have to disarm a nuclear warhead or something, lol. Anyway, that job takes 20+ hours and takes a huge list of parts. Since the OP said they quoted him $2150 I imagine it is the latter job. $2150 seems kind of low, actually.

Replacing the circuit board on the mech unit would be easy to do at home. The mech unit itself is a lot heavier than other valve bodies so get some help or use a jack to support it when removing/installing it.

The sensor module replacement would be pretty tough to do at home. You'll need a few of the special tools for this transmission and lots of patience. Just getting the transmission out is tricky by itself.

Ahh so the mech unit on the Quattro is much more complex than fwd DSGs.
I wouldve thought it would be a simple drop like a valve body from the look of the diagram unless that's the first circuit board you've stated in your post.. Sucks.

[vacsimile]

Ahh so the mech unit on the Quattro is much more complex than fwd DSGs.
I wouldve thought it would be a simple drop like a valve body from the look of the diagram unless that's the first circuit board you've stated in your post.. Sucks.

The longitudinal DSG gearbox is 3-4 times the size of the transverse version, whether it is FWD or Quattro. The mech unit comes out just like a valve body on this transmission. It's a little more tricky on the transverse engines because of limited space.

[Braudy13]

I just got the same warning on my 2010 and luckily did not die yesterday as I was driving on the Hutch near the saw mill in NY, at rush hour and as I slowed to around 30mph for traffic my car went into neutral. I had to stop on the highway and restart my car.......scary! I took it to my Audi dealer and they said it was around a 15h repair job? Luckily I am CPO:)

[rynurz23]

Dealer paid for mine. They knew I had a tune among other mods. They said it had nothing to to with the tune or any other mods.

[danmm7]

Dealer paid for mine. They knew I had a tune among other mods. They said it had nothing to to with the tune or any other mods.

Were you completely our of warranty or under CPO?

I am curious how many people who were out of any warranty got such repair covered or at least 50% covered.

If you do not want to be charged some crazy amount of $$$ , is it even worth going to the dealer if you get the warning message and you're out of warranty?

The other big question that i need to find an answer for is... can these repairs be done cheaper, but well, at any other reputable (Audi knowledgeable) repair facility or this is strictly a 'dealer-only' type of repair.

[nomnomguy970]

Were you completely our of warranty or under CPO?

I am curious how many people who were out of any warranty got such repair covered or at least 50% covered.

If you do not want to be charged some crazy amount of $$$ , is it even worth going to the dealer if you get the warning message and you're out of warranty?

The other big question that i need to find an answer for is... can these repairs be done cheaper, but well, at any other reputable (Audi knowledgeable) repair facility or this is strictly a 'dealer-only' type of repair.
Same here my dealer won't pay for more than 15% of the total cost. I called AoA let's see what they say.

[vacsimile]

Were you completely our of warranty or under CPO?

I am curious how many people who were out of any warranty got such repair covered or at least 50% covered.

If you do not want to be charged some crazy amount of $$$ , is it even worth going to the dealer if you get the warning message and you're out of warranty?

The other big question that i need to find an answer for is... can these repairs be done cheaper, but well, at any other reputable (Audi knowledgeable) repair facility or this is strictly a 'dealer-only' type of repair.

A transmission warning on your DIS does not mean that this repair is required. That's like saying only one thing can turn on your check engine light. At the very least get it checked out by a shop that knows Audis.

As far as who can perform these repairs... Any shop worth their salt can remove the mech unit and replace the circuit board. Easy. If it needs the sensor module the dealer is your best bet, as there are a number of special tools required. It's totally possible to do outside the dealer but I doubt many shops would be interested in doing the job.

[rynurz23]

Were you completely our of warranty or under CPO?

I am curious how many people who were out of any warranty got such repair covered or at least 50% covered.

If you do not want to be charged some crazy amount of $$$ , is it even worth going to the dealer if you get the warning message and you're out of warranty?

The other big question that i need to find an answer for is... can these repairs be done cheaper, but well, at any other reputable (Audi knowledgeable) repair facility or this is strictly a 'dealer-only' type of repair.

I was still under warranty technically.

[Johnnycash]

so just to clarify: is the mechatronics unit inside of the gearbox, or located outside of the transmission? thx

[danmm7]

A transmission warning on your DIS does not mean that this repair is required. That's like saying only one thing can turn on your check engine light. At the very least get it checked out by a shop that knows Audis.

As far as who can perform these repairs... Any shop worth their salt can remove the mech unit and replace the circuit board. Easy. If it needs the sensor module the dealer is your best bet, as there are a number of special tools required. It's totally possible to do outside the dealer but I doubt many shops would be interested in doing the job.

This is interesting and somewhat encouraging.

I have a VAG tool and i can at least scan the car IF and when i get a transmission error on the DIS. I assume the VAG tool will tell me with the right codes if the issue is with the mech unit/circuit board OR with the sensor module?!? Or is this only determined once the transmission is visually inspected/disassembled on the lift?
I guess, what i am getting to is... how much "guessing" can a mechanic (dealer or indy) do before they know for sure what is wrong with the DSG? I know of some mechanics who like to swap expensive parts until they 'fix' the problem. With the S4 DSG unit, this can be a very, very expensive exercise given that i am out of warranty. :(

If any shop with sufficient knowledge can replace the circuit board on the mech unit, i wonder if this can even be done at home garage as DIY project, using the right tools and VAG tool?
I asked that same question few weeks back and someone responded that this is NOT a DIY project due to the extensive coding required to make the new part/board work with the mech unit. True?

[vacsimile]

This is interesting and somewhat encouraging.

I have a VAG tool and i can at least scan the car IF and when i get a transmission error on the DIS. I assume the VAG tool will tell me with the right codes if the issue is with the mech unit/circuit board OR with the sensor module?!? Or is this only determined once the transmission is visually inspected/disassembled on the lift?
I guess, what i am getting to is... how much "guessing" can a mechanic (dealer or indy) do before they know for sure what is wrong with the DSG? I know of some mechanics who like to swap expensive parts until they 'fix' the problem. With the S4 DSG unit, this can be a very, very expensive exercise given that i am out of warranty. :(

If any shop with sufficient knowledge can replace the circuit board on the mech unit, i wonder if this can even be done at home garage as DIY project, using the right tools and VAG tool?
I asked that same question few weeks back and someone responded that this is NOT a DIY project due to the extensive coding required to make the new part/board work with the mech unit. True?

Lets just start and say that these transmissions don't have many failures at all. So don't worry yourself to death over it. If you get a warning (or even if you don't) you can scan it with VCDS but chances are you're not going to be able to really diagnose it. There are bulletins for these repairs so they are easy to diagnose. There are about 10 possible DTC's that can be set when the circuit board dies, and another 10 or so that can be set for the sensor module. The bulletins are also specific about certain freeze frame parameters that have to be within a certain range for the bulletin to apply. You could totally replace the circuit board at home and there isn't any coding required. An adaptation test drive is recommended afterwords but all you really need to do is reset the adaptation values for the clutches.

As for diagnosing other potential issues, because this transmission is so specialized I would only take it to the dealer. If it's an uncommon issue the dealer can contact the corporate technical team who has access to product support who has access to the engineers that designed the transmission. That being said, you always ultimately roll the dice when you take your car to a shop--any shop. You might get the lead tech that will take the time to properly diagnose the issue, or you might get the lazy old man who just tries to sell you a transmission.