DSG 0AM 7 Speed Repair DIY

[@BadDhillon]

Excellent work. Thanks for sharing. Workshops charge over £1,000 for replacing the DSG shift fork bearing in the UK.

[@flyingtools]

Thanks 🙏 Glad that you liked it ☺️

[@stevewaghorn2029]

Your apprentice has a bright future!. Thanks for the video, very helpful. 👍

[@flyingtools]

Thanks, glad I could help ☺️

[@michaelberna987]

Thats so great that you're teaching your children and getting them involved.

[@mashatutube]

Best video I've seen in a century! Nice job!

[@flyingtools]

Wow, thank you so much for that comment ☺️

[@chuggins7998]

Excellent video, thanks. I cannot find anyone prepared to fix my dq200 (same bearing issue as yours). So I’m thinking about trying this. I do not have the tools to remove the clutch. Do you need to remove the clutch to split the gearbox housing?

[@flyingtools]

Thank you so much. Yes you have to remove the clutch, go to local Volkswagen dealer and ask if you can rent that tool for a weekend or so. You do not need to shim the clutch if you use the old clutch again. Thank you for your comment.

[@martialarto2584]

hello and thank you for your video. where did you find the fork bearings and what is their reference?

[@flyingtools]

Hi! I bought it on eBay. Hope this helps😊 www.ebay.com/itm/323984127698?epid=27024927944&hash=item4b6ef576d2:g:5JMAAOSw3o1dXljR&amdata=enc%3AAQAIAAAA4FySAWuYhbAM0QG3HQdNUuWtfpvLm2U0ICUd08NG5wYXFch%2BYZlhAkr%2BpAcnXIGYWBR92l80YXJx7RQCIyAwI3tfeF%2FqDk3BETMdQeiFT5uc595yPMha9COpNE0zPLrALwM5MPlnxRUpLker3P0knkF%2B5wjTV8XDhrSl0zVvMktDaZzXZSX5TT7eK5eKrQ1%2BS5CLKk0TzCVYlj4lHXt%2B1w9%2B%2FvmxsQTdsTs3UOmJ6NVPZUAxe6tFid8PDqthKewJUxzXY4chhj6dzilShoaLcEzSKdWahscaXi0NcJhrZBs1%7Ctkp%3ABk9SR8a_uJTXYg

[@typxxilps]

Well done. How many km did the gearbox had achieved in the car when it happened ?

[@flyingtools]

Hi, and thank you. 110000km.

[@edmondbytyqi4708]

Great explanation. Thank you for posting such a video.

[@flyingtools]

Thank you. I’m glad you liked it ☺️

[@ratataran]

Is there no fluid at all in these things? It looks all dry when you opened it

[@flyingtools]

Of course it is. 1,7liters. But before I opened it up decided to flush it three times with diesel. A good way to get rid of all the metall dust inside of it.

[@rizwanhaque9735]

Hello sir, please could you advise me. I have an issue with me DQ200 DSG 7, it isn't selecting any gears at all and doesn't drive. At idle it makes lots of banging noises, do you think it could be a)flywheel b)clutches or c)gearbox? How can i diagnose?

[@flyingtools]

Hard to say but probably clutch or flywheel. You will probably see that pretty easy when you take out the gearbox.

[@rizwanhaque9735]

@@flyingtools Thank you for the reply! I have removed the gearbox, i am so confused because i dont know what to look for. Where do i begin, what should i look at?

[@bobbondarul7448]

Nice Whe a video about the clutch for this gearbox also? Thank you

[@ranandoublet9537]

Hi I have 7 speed dsg dq200 it’s throwing code p283c it says shift fork c position is that faulty mechatronic or the actual gearbox?

[@flyingtools]

Hi. Sorry, can not say.

[@bonlau1902]

Hello, how do you the gearbox housing screw torque spec? I cannot find it

[@flyingtools]

Hi. I did not find them my self so I just tightened them by my feeling.

[@bonlau1902]

@@flyingtools may i know if can remember the head of the screw? T30 or the other types?

[@kjellbjork5602]

Jättebra video. I min växellåda finns en lös magnet som lossnade på något sätt när jag tog isär växellådan. Ser inte den på din film. Eller är det den du tar bort 1:45 in i filmen?

[@flyingtools]

Tack😃 Nja, innanför mecatroniken ska det inte finnas några magneter mer än magneterna på skiftgafflarna och dom ska inte vara lösa. Jag vill minnas att det däremot låg en magnet monterad i delningen av växellådshusen. Har lite svårt att minnas då jag inte gör dessa jobb vanligtvis. Tack för din fråga och kul att videon uppskattas😊

[@Nur-run85]

Hello you have problèm with gear 2 and 4 already ? With this problem

[@flyingtools]

Hi. No 6 and reverse.

[@Nur-run85]

@@flyingtools i have same problèm with 2 4 6 and Reverse but 1 3 5 7 work well

[@fernandohood5542]

Is that how you change the oil for that gearbox?

[@flyingtools]

Kind of… life time interval on this one.

[@MrMadjoh9]

Sykt bra video den kom veldig mye nytte😁 Måtte du til et vw verkstedet for å regenere/justere mekatronicen etter på? Hvor mye olje fylte du på?

[@flyingtools]

Tack😃 Jag bytte ej kopplingen så jag kunde använda de gamla justerbrickorna. En grundinställning av kopplingen bör en vw verkstad utföra. Det är det enda. Fyllde på 1,7 liter om jag minns rätt.

[@lithatyamzashe6349]

Great Job! Is this what you also have to do should the gearbox screw mount holders get damaged on the actual gearbox? Replace the casing?

[@flyingtools]

Thanks. I’m not really sure what you mean. But if the casing is damage during the pull I would try to repairing that first before I replace it.

[@ThomasHospital-c2z]

Hi, how much kilometers was the gearbox when you noticed the failure? on which engine / car is it installed?

[@flyingtools]

110000km. Golf 7. 1.6 diesel.

[@ThomasHospital-c2z]

@@flyingtools I have a VW Polo V 1.6 Tdi Common rail with the DSG7 DQ200 0AM gearbox that I have driven for 310.000km. The gearbox has often difficulties to shift the reverse or the 1st gear when it is warm. In such case the gear indicator informs that the gear is selected but the car suddenly stops starting and it asks to press the brake pedal so that it can finally select the gear correctly. I have experienced Mecatronic failure at 255.000km and then the mecatronic has been exchanged against an overhauled one and I think that this shifting problem didn't appear before. Today I have Mecatronic failures again and the Mecatronic is removed for repair / upgrade. I have then the opportunity to inspect the selecting mecanism through the Mecartonic holes. What would you advise me to look for in order to diagnose this reverse / 1st gear selecting issue?

[@flyingtools]

Look for excessive play in the shift forks, make sure that the magnets are clean from debris that indicate the fork positions. Not so much more you can do. It sounds to me like you have a faulty mechatronic.

[@michaelberna987]

Do you by chance have a diagram or measurements for the tooling that you created? I want to help a friend with this who can't afford the mechanic fees, so i would like to make the tooling ahead of time if possible so that I don't leave them stranded for too long.

[@flyingtools]

No sadly not.

[@bogdantripon3732]

I got exactly same problem with mine, thanks for the video it did help a lot

[@flyingtools]

Thank you for watching, glad that I could help ☺️

[@jonbagshaw7919]

Trying to split the cases on a OBH very tight do you have to use puller same as yours thanks ?

[@flyingtools]

It is sitting really hard so a puller is a must have.

[@Roverturbo]

Is it possible do you think, to pour boil boiling water from a kettle over the outside of the gearbox casing to expand the aluminium, when taking the casing off and pulling the bearing out the casing, leaving it on the end of the shaft? Rather than use a puller?

[@flyingtools]

No, you need more heat than that, but I’m pretty sure that you need a pulley anyway. Its a very tight fit.

[@Roverturbo]

@@flyingtools ok, thanks, only thought, as I’ve done this before.

[@dsfs17987]

you're not pushing the bearing out of the aluminium housing, you're pressing the shaft out of the bearing, hence the heating the case would provide almost no benefit at all, it is steel on steel situation, and you cannot heat up the bearing race quickly enough to expand it before it transfers the heat into the shaft which also would expand and make the effort pointless

[@Roverturbo]

@@dsfs17987 I also now know there is a circlip holding the bearing inside the gearbox casing.

[@MrMadjoh9]

Hvor langt hadde bilen din ca gått når du byttet den? Var det noe annet spesielt du byttet eller måtte ha av pakninger?

[@flyingtools]

Hej, 13000 mil. Bytte inget annat. Alla tätningsytor mellan halvorna tätas med packningslim.

[@snubbelbuff1471]

Would you happen to know the torque specs for the drain plug on the Mechatronics unit? I have searched high and low for that number but always come up empty handed. All the best!

[@flyingtools]

I will take a look at that and come back to you;-)

[@snubbelbuff1471]

@@flyingtools Very much appreciated! I know the top one is 5 Nm + 90 degrees but I find nothing about the bottom one

[@flyingtools]

@@snubbelbuff1471 I have just checked the workshop manual and you should not drain via the lower screw, you have to remove the mecatronic and drain it via the top screw, thats why you will not find the torque specs for the bottom screw.

[@snubbelbuff1471]

@@flyingtools Ahaa thank you for answer. My local Volkswagen dealer says that the fluid is "lifetime" and that they will simply change the gearbox when it falls apart so I changed the fluid myself (yes through the lower bolt) and the car drives like a dream. Just wanted to ask since you didn't look "lost" around the gearbox. Thank you for video and answering my Q.

[@shimon2476]

@@snubbelbuff1471 Just snug it or it will strip you can drain from the bottom screw as well!

[@huseyinunal7166]

Hello again, I'm sorry, I want to know if the oem number of the DSG transmission oil we used is G 055 512 A2?

[@flyingtools]

Hi, I have to check that on Monday. I do not have it in my head😅

[@Roverturbo]

The dsg oil or the gearbox oil?

[@huseyinunal7166]

@@flyingtools thanks i will be waiting for your reply😄

[@huseyinunal7166]

@@Roverturbo gearbox oil

[@Roverturbo]

@@huseyinunal7166 sorry don’t know the oem number but it’s 75w synthetic.

[@Roverturbo]

Hi, should the driveshaft flanges be stiff to turn normally when gearbox is out the car?

[@flyingtools]

Hi😃 Yes, you can turn them by hand without any tools but it will be pretty hard. Hope it helps. Have a great day and thanks for your question.

[@Roverturbo]

@@flyingtools ok, thanks very much, gearbox is out for a different reason and was quite surprised how stiff it was to turn, completely different from all other gearboxes ive known.

[@miguelbertoni4601]

What did you go study to do this job

[@flyingtools]

Hi. I work as a mechanic for a living but this type of work is nothing that we do at my workshop. This gearbox was sitting in my own car and I did it to save me some money. But now when I have the tools for it, I might do it again.

[@natangonambala1043]

Great work with tools 👌🏽

[@flyingtools]

Thank you 🤗

[@kajman911]

Why not change bearings while the gearbox is apart? 🤔

[@flyingtools]

The bearings was just fine so no need at all.

[@autobossautotrader572]

Can the shift forks be replaced without removing the clutch? Does the clutch have to be removed to take off the cover and remove the gears?

[@flyingtools]

Hi, yes the clutch needs to be removed.

[@autobossautotrader572]

@@flyingtools I have the same tool as you and I also got the same threaded rod setup. When trying to wind up the cover the cover lifts up about a half an inch and the rod and screws on the tool start bending and the cover is not lifting any further. What am I doing wrong?

[@flyingtools]

Have you removed the flange to the left drive shaft? It is fitted with a 6 mm Allen bolt inside the centre of the drive flange.

[@bosswawe6157]

Its something inside holding the cover?

[@flyingtools]

Hi! Yes, the shafts bearings are press-fitted between the covers. And it was sitting so hard so I thought that I destroyed the gearbox!

[@dashcamincident1885]

Why don't change ring gasket??

[@flyingtools]

There is no. Silicon glue is used by the factory.

[@dashcamincident1885]

@@flyingtools I meen another gasket - on the val

[@dashcamincident1885]

@@flyingtools Cuff on the shaft

[@domicars.presov]

where can I buy such bearings?what is the part number?

[@flyingtools]

Hi. I bought it on eBay. Here is a link: www.ebay.com/itm/254705589172?hash=item3b4da2dbb4:g:Rc4AAOSwFNhfTSYK&amdata=enc%3AAQAIAAAA8PLXU5BdyhatdK2e2Kd5XlkLZZgYOaqIEoZdMO1QXJhDeMF4C1E19vpcDE%2BlfwqcQBp%2F1a07zKfF7hyrmGOeLlhpAJOoZZisir09EWRbURz02A15pZym3KbQtSnH%2Fs8Dhnf0anTazYtcig%2B%2BFc4rSW5UR1uIXMOJtx6yqCDN62FkxKWLUaYYoCUW%2FYIwgHNJVFtMRMhP4rNKgA8MIMhfK1wlTEwBghtMN7E5LQE55mE75B7wdbv0Lu%2FVNkWYdMcAOBt8n9iMBWBlevl%2FXCwyEgvYv8cHaH1T5Y8jcVmhyrLIfmTC%2Bgb7PcdD8Nk%2BYSojXg%3D%3D%7Ctkp%3ABFBMnPGKw8Ri Hope it helps😊

[@user-wu-tang]

Hello. Please tell me about error code P074A ? DSG 0AM 7

[@flyingtools]

I have not repaired a gearbox with that error code. But google will give you some info.

[@elevatemed2958]

Hey man can you help me out with a problem, error on dash says transmission faulty please service. Code is P176F00 clutch 2 closes unintentionally. The car won't even start. Would this require a replacement of the mechatronic unit?

[@flyingtools]

Hi! It might be the mechatronic, a little strange that it want even start🤔 It’s a little hard to say what it could be without being there. I wish you good luck anyway.

[@elevatemed2958]

@@flyingtools yea it just displays msg that Transmission faulty and won't start, if the transmission is disconnected then it can start. Seems like mechatronics as you suggested.

[@flyingtools]

@@elevatemed2958 ok, I think your right. In that case I hade replaced the mechatronic.

[@ybeats4718]

How much does it cost if I want your skills to do it on my VW DSG. Thanks

[@flyingtools]

Hi, I’m only doing this for my self, it is very time consuming for me as an “amateur”. But thanks a lot for the question.

[@MrOiphy]

how many bearings are there? 2?

[@flyingtools]

Hi. Yes, 2.

[@huseyinunal7166]

How many liters of dsg oil does this dsg transmission hold ?

[@flyingtools]

If I remember correctly it is 1.7liters.

[@Roverturbo]

Dsg unit oil is 1 litre… gear box oil is 1.7 litres.

[@8520mp]

Μπράβο! Ωραία επισκευή

[@flyingtools]

Thank you sir😊

[@shimon2476]

Hello where did you get the tool pull apart the gearbox

[@flyingtools]

Hi! The poller is a vw tool T10323 that I borrowed from a vw workshop. The rest of it did I made myself. Thanks for your comment 😊

[@shimon2476]

@@flyingtools hey thabks for the reply so the same tool you used to pull the clutch you used to pull open the two halves of the box?

[@flyingtools]

@@shimon2476 yes thats correct.👍🏻 It’s not made for that but it worked pretty good.

[@shimon2476]

@@flyingtools understood thanks brother

[@jcbell78]

Cleaner than a hospital and slick as a surgeon, nice job 👌🏻 Cool truck aswell 😎

[@bwnbwnen8471]

Snyggt jobbat 👍 är i samma situation. Kan du tänka dig ta på dig samma jobb ? Vart i landet finns du 😊

[@flyingtools]

Hej, tack, kul att höra. 😊 Tar tyvärr inte på mig mer arbete än det jag redan har. Hoppas du löser det på ett annat sätt.

[@bwnbwnen8471]

@@flyingtools tack för svar 😊, har nu gett mig på det . Lagren som du visar ska jag byta ut . Verkar som tcu på mechatronic gett upp. Byte ut till en begagnad och flytta över minnet /filen men funkade inte. Har hittat en annan och ska testa igen. Jag har själv en caddy och min vän har en helt ny mechatronic liggandes till en golf 6 med samma motor och dsg. Dock så är mitt nummer 0am325025H ZEQ medans hans slutar på ZE3. De sista ska tydligen vara kodningen till styrningen/tcu. Tror du det funkar ifall jag raderar minnet och flyttar /programmerar in min gamla fil på den nya 😅sorry för långt inlägg men tacksam för svar

[@PedroGonzalez-yr6xd]

Hello excellent channel and excellent video Greetings from Mexico

[@flyingtools]

Hello, thank you 😃

[@bwnbwnen8471]

Grymt bra jobbat , vart i landet finns du 😊

[@flyingtools]

Tack😃

[@anass93.sline.93]

Nice job

[@yeraylopez1376]

Thanks, where can i buy it

[@flyingtools]

I bought it on eBay. Just search for shift fork DSG 7 speed.

[@kippone8260]

Amazing work well done ❤

[@flyingtools]

Thank you😃

[@EandEDesign]

Nice job! Thanks for the video :)

[@flyingtools]

Thank you!

[@andrewchung1838]

DId you have to remove the clutch packs to get to the selector fork for reverse and 6th gear?

[@flyingtools]

Hi, no, just the mechatronic. But before you remove that you have to set all shift forks in neutral. You can do that either with your diagnostic tool BEFORE you take out the gearbox from the car, or as I did in this case, via the selector cover.

[@andrewchung1838]

@@flyingtools Thanks for the reply. I have a 2015 Polo GTI. Did VW put upgraded bearings for the selector fork? Or will I encounter this problem eventually in my polo? Thank you!

[@jannejarvinen790]

Not even a single drop of gearbox oil, how have got all away ?

[@flyingtools]

I filled it twice with brakeclean before I opened it up.

[@AhmedMohamed-hk3io]

You are amazing.. look like German bodybuilder called Denis wolf

[@flyingtools]

Thank you. Wow hahaha, that guy was not small. Have a great day and thank for your comment😊

[@misa000]

Why the Music ? Otherwise great video

[@flyingtools]

Well, this was one of my first videos ever posted and at that moment it felt right, now almost 200 videos later, I might have done it a bit differently… Glad that you liked it anyway.

[@tahirayuob6887]

Good job mate

[@flyingtools]

Thanks!

[@gustavolopez421]

I like video 👌

[@flyingtools]

Thank you😃

[@kjellbjork5602]

Jättebra video. I min växellåda finns en lös magnet som lossnade på något sätt när jag tog isär växellådan. Ser inte den på din film. Eller är det den du tar bort 1:45 in i filmen?

[@flyingtools]

Hej igen, se mitt svar i din tidigare kommentar. Tror du råkade skicka två ggr. 😊