Dsg harsh shifting [Archive]

Audi_here

10-22-2018, 07:06 PM

So long story short... I have a 14 s4 unitronic dual pulley. I was stage 1 for a year then went stage 3. Immediately after install of the stage 3 tune the dsg box started to slam into every gear. Tuned back to stock and problem kept happening. After multiple dsg readaptations the problem did not go away and just got worse. After bringing to audi and getting td1 and asking them to find the problem they tried to readapt the dsg themselves and the car threw shift fork a solienoid malfunction codes. They could not clear it. So as unitronics recommendation I went ahead and replaced the whole transmission for a insane amount of money. I was stock for about two weeks prior to new transmission and everything was fine. Then loaded the single pulley tune and dsg tune on to the car, and Bam problem is back. Flashed back to stock and problem persist. Unitronic plays stupid and says it has nothing to do with them. Can't afford another transmission. And the car is barely driveable with no codes(check with vcds every day). Also have tried multiple readaptations but problem just gets worse and worse. Anybody have the same issue or have any tips on a fix without dsg replacement?

Gberg888

10-22-2018, 07:51 PM

Welcome to shitty DSG...

Try IKQ or car-parts for a replacement tranny for cheapish...

I am dealing with the gear selector sensor issue on mine... 4k later.

Grigor@Bestiale

10-22-2018, 08:13 PM

If by new transmission you mean brand new from the dealer and it’s installed properly, then 99% the issue is with the tune(s). What does Unitronic say?
Do you have a full scan of the issue with the old transmission and with the new one?

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PopTart

10-22-2018, 08:25 PM

It could be the Mechatronics Unit ($5,000), or just the Circuit Board ($1,500)

JacobCat

10-22-2018, 09:13 PM

It could be the Mechatronics Unit ($5,000), or just the Circuit Board ($1,500)

Should those both not be included in a new transmission anyways? Should already be brand new in OP's situation.

Bartlett

10-23-2018, 12:31 AM

Should those both not be included in a new transmission anyways? Should already be brand new in OP's situation.

Yeah, OP should have everything new. If he still has a problem, it sounds like it’s the tune and perhaps a specific DSG box code.

I haven’t really heard squat from Uni when it comes to tune updates. So, I wouldn’t be surprised if an anomaly has been found.

PopTart

10-23-2018, 01:05 AM

Where did you buy the Transmission from? The Dealership has to offer a 1yr warranty.

bhvrdr

10-23-2018, 02:24 AM

Id want to know what came with the new transmission and what was swapped over. To be clear you did flash back to stock and still have the issue?

Also to clarify you mentioned in another thread that you snapped the shift fork on your last transmission. Was this verified to be the failure or is that what was suspected but never verified?

BTW, Yes id bring it back to the dealer.

Mike

ANMS4

10-23-2018, 05:42 AM

catalyst686

10-23-2018, 07:58 AM

Just out of curiosity how much did the new tranny run?

PopTart

10-23-2018, 10:43 AM

First sorry to hear of the issues, agree with the above, if you installed a new tranny reflashed the tune and the issues came right back it's the tune for sure,

Also he can't go back to the dealer he was already flagged, so they know he had a tune, I'd think they'd make him pay again for new tranny and not warranty anything :(

Despite TD1, I think they'd still help him. Not offer a Warranty per se. If he's on good terms with the Advisor/Manager, they'll give him suggestions. Also, if you bring a used Transmission to the dealership, they can install it. They won't warranty the part, but you just pay the Labor Fee.

bhvrdr

10-23-2018, 11:05 AM

again, the important thing to find out is what parts were new and what parts were swapped over.

If you really did snap a shift fork on your first transmission i'm assuming they ordered you a new gearbox.

I have no idea what comes pre-installed on a factory new DSG box p/n: 0B5300056C003. They may or may not have to also order other new parts like mechatronics or otherwise they would have to swap over the old ones.

You also want to find out if you really did snap the shift fork on your first transmission. Was it just the code it through or did they inspect and find that was actually the failure.

This is important because you dont want to keep having the same issue.

Can you post a copy of your invoice with the parts on it to see what they actually replaced?

Mike

Audi_here

10-23-2018, 12:54 PM

Sorry guys. At work. Lkq dsg swap. With half my milage. About 32k miles. Done by the highest rated audi shop in my region. Traveled quite a ways to have the work done. Sorry for the confusion. Used tranny. But nothing was swapped between them. So different mech unit, clutch and everything. Had uni change my file to match the mech unit in this dsg. But same issue. Going back to stock does not help. I've blamed the tune multiple times on them straight to the tech directors face. He laughs and says impposible. Always have had issues with their tune from day one. Regret it completely. Used dsg swap parts in labor was $5500. What's insane is that just a couple weeks before I had the dmf and clutch pack replaced due to slipping. Was perfect after. Then flashed to stage 3, blew the trans, replaced, blew once tuned again. No codes still on this box but may throw them if I go to audi. But exact same issue. From what I understand the issue seems mech unit related. As the fork operation is control by solenoids on the mech valve block. I do have warranty from lkq but after spending over $10k in dsg repairs in one month I can't afford the labor to install or even to get rid of the car. (upside down). I'm a tech my self. But dont have time to replace a whole transmission at work. Mech unit is easy. Can do that in a few hours or less.

Audi_here

10-23-2018, 12:55 PM

Just code. I have my old transmission at home. But will need a engine cram to separate the box in order to inspect. May pull the mech out and see the condition of gs valves.

doanut

10-23-2018, 01:53 PM

Seems like it's tune related. If you do replace it, run a stock DSG tune and see how you go. Then if you roll the dice again maybe look for another tuner.

bhvrdr

10-23-2018, 02:14 PM

Thats just random and strange. Its an interesting troubleshooting case.

I say that because like you said you replaced all components so thats that. Then on the other hand its not like Unitronic made a special file for you that immediately blows transmissions yet the other thousands of flashed folks get away clean.

So whats going on with your car specifically? Be interesting to monitor your your transmission was behaving prior to it blowing. If you do swap in another unit make sure you datalog it continuously for quite some time.

Audi_here

04-20-2019, 02:55 PM

Morritse

04-20-2019, 02:59 PM

in case anybody wanted an update, another transmission did not fix this issue. the car is completely fucked, odd lean outs, loping idle, incorrect shift points, dropping boost randomly, stalling randomly.

What a nightmare man. I really hope you can get to the bottom of the issue and the people who caused it be held accountable.

bhvrdr

04-20-2019, 04:54 PM

in case anybody wanted an update, another transmission did not fix this issue. the car is completely fucked, odd lean outs, loping idle, incorrect shift points, dropping boost randomly, stalling randomly.

I assume you are back stock now?

Can you do some logging?

Audi_here

04-21-2019, 05:48 PM

ive been stock and now im on single pulley file to increase the symptoms to help me chase it, what im seeing so far is if the car is left at idle for a long period of time the fuel trims start to go up towards 20%, no codes, it acts like it has a vacuum leak, especially the way the FTs behave but i have not found any, even at work our shop foreman pulled all the special service tools out and we could not find one leak. on acceleration i see the down stream sensors peg 100mv until the car gets above 5k rpm and they even out to 750mv, lambda stays on point. but if it shifts while the downstream sensors read 100mv it will bang into gear. the sensors do not switch back and forth which would be in line with bad cats.

wangshuo1989

04-22-2019, 03:09 PM

Have you tried any other tuners?

Audi_here

04-22-2019, 04:11 PM

bhvrdr

04-22-2019, 04:18 PM

Its funny you mentioned vacuum leak it made me think the same thing. I wonder if youve ever actually needed a transmission replaced. I wonder if something is messing with throttle control causing these behaviors. So strange. You get no softcodes at all?

Audi_here

04-22-2019, 06:08 PM

this is exactly what im thinking too. no codes. not one code that i havent caused in two years of ownership

bhvrdr

04-22-2019, 06:12 PM

this is exactly what im thinking too. no codes. not one code that i havent caused in two years of ownership

Check all the vacuum selenoids on back of sc? My house is packed up right now for a move or id send you my stock tb just to rule it out.

Audi_here

04-22-2019, 09:48 PM

i would appreciate that, ive checked everything, but i haven't been able to try a throttle body swap, but we had a thought it could be related as its a slightly common failure on the s4/s5, but they always throw a code way before the symptoms show up.

Joker S4

04-23-2019, 05:14 AM

raudiace4

04-23-2019, 06:23 AM

Man that is brutal. It sounds like it must be tune related, before you go replacing the trans again might be worth it to try another aftermarket tuner's DSG software on it. That way you can prove it was something Unitronic did. It clearly wasn't the dealer install, since you said the car ran fine for two weeks before the Unitronic DSG software.

bhvrdr

04-23-2019, 06:47 AM

the fact that this happens even when i got back to the stock files leads me to believe that it isn't tune related. i even performed s/w updates at work as well is ran a spec/actual to set everything back to factory settings and it didnt help

Man that is brutal. It sounds like it must be tune related, before you go replacing the trans again might be worth it to try another aftermarket tuner's DSG software on it. That way you can prove it was something Unitronic did. It clearly wasn't the dealer install, since you said the car ran fine for two weeks before the Unitronic DSG software.

Its not tune related and i doubt hes going looking for another transmission since it may not have been the trans. Its a weird situation. IIRC he had issues where the car would literally just downshift on him without throttle input.

Audi_here

04-24-2019, 07:01 PM

yes it will, for example coasting at high speeds it will kick down from 7th to 3rd so when i get on the throttle i just bang the limiter. im unsure where to go at this point, i can get mech units pretty cheap with my discount at work, but i dont understand why i would need to even replace it as these transmission all have there own mech. lately its been up shifting in to high gears at very low speeds so it gets to a point where it feels like its going to stall. just to see if it makes a difference ill have to spend $1600 on a mech unit, which is absurd.

Audi_here

04-24-2019, 07:03 PM

I have a stock TB that I could let you try out if you're interested.

message me

Grigor@Bestiale

04-24-2019, 07:35 PM

Damn, this is indeed getting crazy...
Just to make sure, did you:
1. switch all tunes ECU and TCU to stock
And
2. Reinstall all OE parts on engine and trans
With these conditions: do you still get the weird shifting (eg 7th to 3rd at high speed)?

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evanb

04-25-2019, 03:21 PM

This is all way beyond my expertise, but it sounds like what happens when you hit the kick down switch. Perhaps a short.

AudiS4SD

04-27-2019, 05:18 AM

Any updates to this OP?

Audi_here

04-27-2019, 08:25 AM

Any updates to this OP?

nothing much yet, but as of last night i noticed that there is a lean out as soon as it goes into to 4th all the way through 7th, seems as though when the car shifts to 4th the bypass starts closing and enters boost and thats when all my problems occur.

m0n4g3

04-27-2019, 10:57 AM

Just throwing this out... i'm no means a mechanic but...

Since it's leaning out only on boost... could it be the MAP sensor?

Audi_here

04-27-2019, 01:37 PM

Just throwing this out... i'm no means a mechanic but...

Since it's leaning out only on boost... could it be the MAP sensor?

replaced all of them already

Audi_here

04-27-2019, 01:46 PM

another update, i let my car idle for about 45 minutes today, when i came back to it it was idling around 500rpm, plugged in vcds and watched some pids, when i blipped the thottle the revs hung around 2200 for a few seconds and then fell back down and the car stalled. it start right back up, i did this every time until i drove it. my intake and charge temps were around 180f and vacuum was fine at idle but right after i blip the throttle intake vacuum shoots up vac will stay high until the car stalls. it should go high and instantly go back to normal vacuum, this points toward clogged cats, but i had previously installed test pipes because i had thought the cats were bad and all of these symptoms that im having were still there, so i reinstalled the cats because i couldn't stand the sound of the test pipes.

Audi_here

04-27-2019, 01:50 PM

Just throwing this out... i'm no means a mechanic but...

Since it's leaning out only on boost... could it be the MAP sensor?

also ive tested them all with the VAS map tester. its a digital gauge wich taps into the s/c and map sensors and gives you a real reading of intake pressure, you compare the live reading from the gauge with the live reading from the map sensors on the scan tool. if there is a difference between the scan tool reading and the gauge your map sensor is bad.