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DSG clutch replacement

DSG (Direct Shift Gearbox) dual-clutch transmissions offer outstanding shift speed and driving dynamics, but just as on a manual gearbox, their clutches are wearing parts. Because a dual-clutch system consists of two separate clutch packs (one for the even gears and one for the odd gears), it places very high demands on the components. Worn clutches cause jerky shifting and slipping and can eventually lock the transmission completely. At Carstop workshops we use specialist tooling to carry out professional replacement of wet and dry DSG clutches (including the VAG group DQ200, DQ250, DQ500 and others), restoring your car’s original smooth driving comfort.

Carstop workshops include the following among their maintenance services

Removal of the worn DSG dual-clutch pack and installation of a new one
Inspection and replacement of the dual-mass flywheel, shaft seals and selector forks
Post-replacement mechatronics basic setting, adaptation and test drive

How to recognise when you should bring your car in for a check

Noticeable shudder, jerking or knocking when pulling away or changing gear
If a DSG-equipped car starts to shudder or jerk noticeably when pulling away or at low revs (especially shifting from 1st to 2nd), this points to uneven wear or glazing of the clutch plates. A metallic knock or rattle at the moment of the gear change can also indicate wear.
Gears "slip" under acceleration, or the even/odd gears disappear altogether
If you press the accelerator but the engine revs rise without the car gaining speed, the clutch plates are worn and slipping. In the event of critical wear, the mechatronics unit shuts down one half of the clutch entirely for safety, leaving your car able to drive only in, for example, 1st, 3rd and 5th gear.

Read more about the service

Why does DSG clutch replacement require specialist tooling and specially trained mechanics?
Unlike an ordinary manual gearbox, fitting a DSG dual clutch is a fine adjustment accurate to the millimetre. When installing a new clutch pack, the locking washers must be aligned very precisely with special measuring tools and the clutch's initial position set. Incorrect fitting or a measurement error will destroy a new clutch within just a few thousand kilometres.
Do other components or the oil also need renewing during DSG clutch replacement?
Yes — when replacing the clutch kit we strongly recommend also replacing the dual-mass flywheel, as its service life is similar to that of the clutches and the transmission is already removed. Wet-clutch transmissions are also always refilled with new specialist DSG oil and the filter is replaced, to guarantee flawless hydraulic operation of the new system.
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