Repairs We've Solved — Case Studies

The fault

Customer reported the DSG gearbox slipping and jerking once the car reached operating temperature, with a gearbox warning light appearing intermittently. Two previous garages had reset the adaptations and sent the customer away.

Diagnosis

Road test confirmed the slip under load when warm. Computer diagnostics flagged mechatronic pressure deviations. We carried out a full clutch and mechatronic adaption reset and pressure test, isolating a failing clutch pack rather than the mechatronic unit.

Repair process

Dropped the DSG unit, replaced the dual clutch pack with a quality reconditioned assembly, refitted and performed a full adaption and basic setting sequence. Fluid replaced with correct specification.

The fault

The hybrid system warning light would come on after 20 minutes of driving, then clear after a restart. A main dealer had quoted for a full hybrid battery replacement.

Diagnosis

We ran a full high-voltage diagnostic and battery health check. The battery blocks were healthy — the fault was a failing DC-DC converter under thermal load, not the traction battery.

Repair process

Replaced the DC-DC converter, cleared the stored codes, and carried out a full hybrid system health check and cooling system inspection to confirm no underlying cause.

The fault

Car went into limp mode with no drive in higher gears. Local garage replaced a solenoid at random with no improvement.

Diagnosis

Computer diagnostics and a road test pointed to a valve body issue inside the Multitronic unit. We confirmed the fault with a hydraulic pressure test before recommending any parts.

Repair process

Removed and rebuilt the valve body, replacing worn solenoids and cleaning the hydraulic circuit. Refitted with fresh fluid and a full adaption reset.