The DSG valve body is definitely one of the simplest we have seen in transmissions (see figures 1 through 5). It contains only five valve line-ups, two checkballs, three damper assemblies, two pressure senders (pressure sensors/transducers) and 13 filters (see figures 2, 3 and 5).
Although the DSG 02E transmission contains 11 solenoids, they could be placed into three categories: gear actuator, pressure control and TCC. This article covers the first group and part of the second, and next month’s article will cover the rest of the second group and the third.
Housed inside the six-speed direct-shift gearbox (DSG) is a Mechatronics assembly consisting of a control module, valve body and solenoids (see figures 1 and 2). 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.
Volkswagen’s direct-shift gearbox DSG 02E (see Figure 1) is used in the United States in some 2004-to-present New Beetle, New Jetta and Golf GTI models. It is a six-speed manual front-wheel-drive gearbox that is shifted automatically.
Which brings us to the meat of this article, which is BorgWarner’s DualTronic™ six-speed transmission, otherwise known as a DSG (direct shifting gearbox) or AMT (automated manual transmission), which was adopted by Volkswagen and Audi when the VW Golf R32 and the Audi TT 3.2 made their debuts.