Comprehensive Remanufacturing Solution for Volkswagen and Audi 7-Speed DSG Transmission Control Unit Issues

If you own a Volkswagen or Audi vehicle equipped with the 7-speed Direct Shift Gearbox (DSG) and are experiencing transmission problems, particularly with the DQ200 control unit, you’re not alone. This issue is prevalent in vehicles produced between 2003 and 2016. Common symptoms include a loss of drive, illuminated EPC light, flashing gear symbols, and a blown 30-amp fuse. One of the main culprits is the DSG 7 control unit, leading to fault codes such as P189C, P0562, and P1604.

This DSG 7 control unit is a very common failure for vehicles built between 2003 – 2016 fitted with the DQ200 Direct Shift Gearbox (DSG). The most common reported symptom is a complete loss of drive due to not being able to select any gears, this will cause the EPC light to remain illuminated and the gear symbols will continually flash on the instrument panel. Often the main 30-amp fuse will be blown, if you try to replace the fuse it will blow again while the DSG control unit remains connected.

 

If you attempt to read the fault codes stored in the gearbox system, then you may also notice the gearbox system fails to communicate with your diagnostic scanner, preventing you from reading any fault codes. However, if you are able to communicate with the DSG gearbox system, then you may have the following fault codes stored:

 

• 16946/P0562/001378 – System Voltage Low
• 005636/P1604 – Internal Control Module
• P189C/006300 – Function Restriction Due To Insufficient Pressure Build-up.

If you are experiencing any of the above issues, then this is usually a clear indication that your DSG 7 control unit has failed.

 

We are able to remanufacture (rebuild) your own DSG unit and supply an unlimited mileage lifetime warranty as standard. When we rebuild your own unit, we use higher rated than standard components and ‘engineer out’ the original design flaw that caused your unit to fail in the first place, giving you the peace of mind that your unit will not fail again. If we rebuild your own unit then it will cost a small fraction of the cost of a new unit, and you will not need to program the unit back onto your car – simply refit, replace the oil and away you go.

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Our Solution: Remanufacturing Your DSG Unit

We specialise in remanufacturing (rebuilding) your existing DSG unit, offering an unlimited mileage lifetime warranty. By utilizing higher-rated components and addressing the original design flaw, we ensure your unit performs better than the factory version. This cost-effective solution eliminates the need for expensive programming onto the vehicle, allowing you to refit the unit, replace the oil, and resume driving.

Supported Models:

• Audi A1 (2010 – 2018)
• Audi A3 (2007 – 2017)
• Audi Q2 (2016 – 2018)
• Audi Q3 (2011 – 2018)
• Audi TT (2008 – 2014)
• Seat Altea (2009 – 2015)
• Seat Ibiza (2008 – 2015)
• Seat Toledo (2012 – 2015)
• Seat Leon (2009 – 2018)
• Skoda Fabia (2010 – 2016)
• Skoda Octavia (2008 – 2018)
• Skoda Rapid (2012 – 2015)
• Skoda Roomster (2010 – 2015)
• Skoda Superb (2008 – 2019)
• Skoda Yeti (2009 – 2015)
• Volkswagen Beetle (2011 – 2015)
• Volkswagen Caddy (2010 – 2015)
• Volkswagen Golf (2008 – 2017)
• Volkswagen Jetta (2009 – 2014)
• Volkswagen Passat (2009 – 2018)
• Volkswagen Polo (2009 – 2015)
• Volkswagen Scirocco (2008 – 2014)
• Volkswagen Touran (2010 – 2015)

Common Failure Symptoms:

• No gear engagement
• Loss of drive or reverse
• Illuminated EPC light
• Constant blowing of the main 30-amp fuse

Common Fault Codes:

• P189C (06300) – Function Restriction Due To Insufficient Pressure Build-up
• P0562 (16946/001378) – System Voltage Low
• P1604 (005636) – Internal Control Module
• P17BF (06079) – Pump Protection Maximum Limit Reached

Common failing part numbers:

• 0AM 927 769 D
• 0AM 927 769 K
• 0AM 927 769 G
• 0AM 325 025 D 
• 0AM 325 025 H 
• 0AM 325 065 N 
• 0AM 325 025 J

 

A brand-new unit from the manufacturer is very expensive and will require programming onto the vehicle which adds further labour costs. Most worryingly is that the brand-new unit that we have seen still have the original design flaw, so if you purchase a new replacement unit then you can expect it to fail again at some point down the line.

Outperforming the original:

This is a complete re-engineered solution for the DSG-7 family of mechatronics units, all failing components are replaced with our own re-engineered versions, designed from scratch to outperform the original OEM parts. Employing our in-house designed reinforced stainless-steel pressure build-up controls, polymer clutch actuation protection and control unit revision, complete HIL simulation redesign to ensure all shift actuators are meeting and exceeding original OEM specifications in real-world conditions.

Unable to select gear 6 and/or reverse: 

The VW/Audi group DSG7 DQ200 mechatronic will typically cause gear change problems on the vehicle. However, it’s not always the mechatronic unit that causes drivability problems.Gear selector fork failure will cause the symptoms outlined below and if not rectified can cause serious damage to the gearbox.

Programming and Installation:

All coding is retained during test and rebuild – no need for programming once you receive your rebuilt DSG7 unit back. Just fit as below and go!

Common Failure Symptoms:

• Gears Grinding/Crunching
• PRNDS Lights Flashing
• Unable To Select Gear 6
• Unable To Select Reverse
• P072C – 01851 – Stuck In Gear 6

Remanufacturing Process:

Our remanufacturing process involves a complete re-engineering of the DSG-7 mechatronics unit, replacing failing components with enhanced versions designed to outperform the original OEM parts. Rigorous testing, both before and after the rebuild using Hardware In-the-Loop (HIL) DSG-7 Gearbox rig, ensures that each unit meets and exceeds OEM specifications.

Quality Assurance and Warranty:

Our strict quality control standards, encompassing testing, components, and workmanship, guarantee the highest level of work. We back our remanufactured units with a lifetime unlimited mileage warranty, providing you with peace of mind.

How to Get Your Unit Repair:

1. Select your model on our website and click “Get yours Repaired.”
2. Print the payment/booking confirmation email.
3. Package the DSG7 transmission control unit securely with the confirmation email.
4. Send the package via tracked courier.

For those who prefer not to pay upfront, an alternative option is available, involving a pre-rebuild test and payment after confirmation of faults.

If you have further inquiries or need additional information, please don’t hesitate to contact us.
Contact AUTOTRONICS at 0116 276 7054 or email us at [email protected] for expert assistance. Our experienced engineers are here to solve all your queries and provide top-notch services.

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