0AM 7 speed DSG - wont complete basic settings

[DGMotors]

Anyone have any ideas on why a basic setting won't complete?

0AM DSG 7 speed gearbox - Audi A4 1.4 TSI twincharge
Came in with a slipping clutch
We have fitted a new clutch pack and flywheel and come to do the clutch adaptions and basic settings but it wont compete. Starts off like normal once you get to 4-0-0 you start the engine and briefly flashes on the next screen and then goes back to 4-0-0 and sits there.

Gearbox details:
Part No SW: 0AM 300 058 A HW: 0AM 927 769 D
Component: GSG DSG AG7 441 4531
Revision: 00044014 Serial number: CU501706257062
Coding: 0000016
Shop #: WSC 00046 000 00000
VCID: 2F677CC5BEE888FCAA-807A

060 Log from VCDS:
253 19 140
253 19 140
253 19 140
253 19 141
253 19 141
253 19 141
253 19 141
253 19 141
253 19 141
253 19 142
253 19 142
253 19 142
4 0 0
4 0 0
4 0 0
*** Engine started ****
253 4 126
253 4 126
253 4 126
253 4 126
4 0 0
4 0 0
4 0 0
4 0 0

Autoscan from car:

Monday,18,January,2021,16:02:21:62916
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x64
VCDS Version: 20.12.0.0 (x64)
Data version: 20201124 DS322.0
www.Ross-Tech.com

Dealer/Shop Name: DG Motor Services

VIN: WAUZZZ8X2EB032623   License Plate:


Chassis Type: 8X-AU21 (8U0)
Scan: 01 02 03 08 09 15 16 17 19 25 42 44 46 52 5F 62 72

VIN: WAUZZZ8X2EB032623   Mileage: 185380km-115189miles

01-Engine -- Status: OK 0000
02-Auto Trans -- Status: OK 0000
03-ABS Brakes -- Status: OK 0000
04-Steering Angle -- Status: OK 0000
08-Auto HVAC -- Status: OK 0000
09-Cent. Elect. -- Status: OK 0000
15-Airbags -- Status: OK 0000
16-Steering wheel -- Status: OK 0000
17-Instruments -- Status: OK 0000
19-CAN Gateway -- Status: OK 0000
25-Immobilizer -- Status: OK 0000
42-Door Elect, Driver -- Status: OK 0000
44-Steering Assist -- Status: OK 0000
46-Central Conv. -- Status: OK 0000
52-Door Elect, Pass. -- Status: OK 0000
5F-Information Electr. -- Status: OK 0000
62-Door, Rear Left -- Status: OK 0000
72-Door, Rear Right -- Status: OK 0000
 
-------------------------------------------------------------------------------
Address 01: Engine (J623-CTHG)       Labels:. 03C-907-309-V1.clb
   Part No SW: 03C 906 026 AD    HW: 03C 907 309 P
   Component: 1.4l R4 TSI   H02 4526 
   Revision: LLH02---    Serial number:               
   Coding: 00250012000400000000
   Shop #: WSC 06325 000 00000
   ASAM Dataset: EV_ECM14TSI01103C906026AD 001005
   ROD: EV_ECM14TSI01103C906026AD.rod
   VCID: 62C1C5F175BA759475-8036

No fault code found.
Readiness: 1110 0101

-------------------------------------------------------------------------------
Address 02: Auto Trans        Labels: 0AM-927-769.clb
   Part No SW: 0AM 300 058 A    HW: 0AM 927 769 D
   Component: GSG DSG AG7     441 4531 
   Revision: 00044014    Serial number: CU501706257062
   Coding: 0000016
   Shop #: WSC 00046 000 00000
   VCID: 2F677CC5BEE888FCAA-807A

No fault code found.

-------------------------------------------------------------------------------
Address 03: ABS Brakes (J104)       Labels:. 6R0-907-37x-ESP90.clb
   Part No SW: 6R0 907 379 BR    HW: 6R0 907 379 BA
   Component: ESP9.0i front H03 0003 
   Serial number: --------------
   Coding: 33DF688B442602C2CC1A166B2254408D1104
   Shop #: WSC 00046 412 00000
   ASAM Dataset: EV_Brake1ESP90iBOSCH 003031
   ROD: EV_Brake1ESP90iBOSCH_003_VW21.rod
   VCID: 0F27DC45D6A8A8FC8A-805A

No fault code found.

-------------------------------------------------------------------------------
Address 08: Auto HVAC        Labels: None
   Part No SW: 8X0 820 045 A    HW: 8X0 820 045 A
   Component: J255 Klima Manuell  0150 
   Revision: 0000708S    Serial number: 03030023840235
   Shop #: WSC 00046 000 00000
   VCID: 346D73A957CEAB24D7-8060

No fault code found.

-------------------------------------------------------------------------------
Address 09: Cent. Elect. (J519)       Labels:. 8X0-907-063.clb
   Part No SW: 8X0 907 063 N    HW: 8X0 907 063 N
   Component: BCM PQ35  M   112 0771 
   Revision: AG112771   
   Coding: 0E000A2CA805F1C0201843E020000154538B6C0A01CF4922DC0800830040
   Shop #: WSC 00046 000 00000
   VCID: 47973465F65830BC82-8012

   Subsystem 1 - Part No: 8X0 951 177
   Component: DWA-Sensor H0  H01 0020

   Subsystem 2 - Part No: 1K0 951 605 C
   Component: LIN BACKUP HO  H05 1501

No fault code found.

-------------------------------------------------------------------------------
Address 15: Airbags (J234)       Labels:| 8X0-959-655.clb
   Part No SW: 8X0 959 655 B    HW: 8X0 959 655 B
   Component: Airbag10.41   H06 0009 
   Revision: --------    Serial number: 003KZ0065AYR
   Coding: 30323236303230303138554A305238583053
   Shop #: WSC 00046 000 00000
   ASAM Dataset: EV_Airba1041BPAAU210 001018
   ROD: EV_Airba1041BPAAU210.rod
   VCID: 4993325DE84CC6CC94-801C

   Crash sensor for side airbag: driver side:
   Serial number: 3554VRB400S50JAUL9KH

   Front Passenger's Side Airbag Crash Sensor:
   Serial number: 3575HRB401I50I7EG0RD

   Crash sensor for front airbag: driver side:
   Serial number: 3585HRB404T20N96516-

   Rear end impact crash sensor:
   Serial number: 3515ZRB400O50KJK6H6-

No fault code found.

-------------------------------------------------------------------------------
Address 16: Steering wheel (J527)       Labels:| 8X0-953-569.clb
   Part No SW: 8X0 953 501 B    HW: 5K0 953 569 H
   Component: LENKS.MODUL   016 0140 
   Revision: FF010018    Serial number: 20130819100497
   Coding: 1994004000
   Shop #: WSC 00046 412 00000
   ASAM Dataset: EV_VW360SteerWheelUDS A03004
   ROD: EV_VW360SteerWheelUDS.rod
   VCID: 3973429DB8AC564C04-806C

   Multifunction steering wheel control module:
   Subsystem 1 - Part No SW: 4G0 951 528 A    HW: 4G0 951 528 A
   Component: E221 - MFL  H08 0010

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments (J285)       Labels:| 8X0-920-xxx-17.clb-SRI1
   Part No SW: 8X0 920 980 M    HW: 8X0 920 980 M
   Component: KOMBI_MEDIUM  H01 0330 
   Serial number: 00000000000000
   Coding: 43CE00
   Shop #: WSC 00046 412 00000
   ASAM Dataset: EV_Kombi_UDS_VDD_AU10 A04399
   ROD: EV_Kombi_UDS_VDD_AU10.rod
   VCID: 4993325DE84CC6CC94-801C

No fault code found.

-------------------------------------------------------------------------------
Address 19: CAN Gateway (J533)       Labels: 8X0-907-468.clb
   Part No SW: 8U0 907 468 Q    HW: 8U0 907 468 G
   Component: GAT 4CAN 1L M H13 0063 
   Revision: 1P120037    Serial number: 3741P1373100C1
   Coding: F0C40064000100010353
   Shop #: WSC 00046 000 00000
   VCID: 50A51F390316F704D3-8004

No fault code found.

-------------------------------------------------------------------------------
Address 25: Immobilizer (J334)       Labels:| 5K0-920-xxx-25.clb
   Part No SW: 8X0 920 980 M    HW: 8X0 920 980 M
   Component: IMMO          H01 0330 
   Serial number:               
   Coding: 000002
   Shop #: WSC 00046 412 00000
   ASAM Dataset: EV_Immo_UDS_VDD_AU10 A04113
   ROD: EV_Immo_UDS_VDD_AU10.rod
   VCID: 4993325DE84CC6CC94-801C

No fault code found.

-------------------------------------------------------------------------------
Address 42: Door Elect, Driver (J386)       Labels:. 8X0-959-793.clb
   Part No SW: 8X0 959 793 K    HW: 8X0 959 793 K
   Component: TSG FA        H10 0415 
   Revision: --------    Serial number: --------------
   Coding: 011E02200001000000
   Shop #: WSC 00046 000 00000
   VCID: 55ABEE2D3CF4922C00-8000

No fault code found.

-------------------------------------------------------------------------------
Address 44: Steering Assist        Labels: 6Q0-423-156.clb
   Part No: 6R0 423 156 C
   Component: LenkhilfeTRW        V278 
   Coding: 11251
   Shop #: WSC 00046 
   VCID: 30657FB9F7D69704B3-8064

No fault code found.

-------------------------------------------------------------------------------
Address 52: Door Elect, Pass. (J387)       Labels:. 8X0-959-792.clb
   Part No SW: 8X0 959 792 K    HW: 8X0 959 792 K
   Component: TSG BF        H10 0415 
   Revision: --------    Serial number: --------------
   Coding: 011E02200001000000
   Shop #: WSC 00046 000 00000
   VCID: 54AD1329370E8B24F7-8000

No fault code found.

-------------------------------------------------------------------------------
Address 5F: Information Electr. (J794)       Labels: None
   Part No SW: 8X0 035 183 F    HW: 8X0 035 183 D
   Component: RMC Cnct      H54 0801 
   Coding: 01010401008051070023000103010000010000
   Shop #: WSC 00046 000 00000
   VCID: 3A715D91B5AA5D540D-806E

   Subsystem 1 - Part No SW: 8X0 919 603 A    HW: 8X0 919 603 A
   Component: DU6 Basic  H43 0084
   Serial number: 9462H10D2691585     

No fault code found.

-------------------------------------------------------------------------------
Address 62: Door, Rear Left (J388)       Labels:. 8X0-959-795.clb
   Part No SW: 8X0 959 795 D    HW: 8X0 959 795 D
   Component: TSG HL        H07 0415 
   Revision: --------    Serial number: --------------
   Coding: 010802200001000000
   Shop #: WSC 00046 000 00000
   VCID: 50A51F390316F704D3-8004

No fault code found.

-------------------------------------------------------------------------------
Address 72: Door, Rear Right (J389)       Labels:. 8X0-959-795.clb
   Part No SW: 8X0 959 795 D    HW: 8X0 959 795 D
   Component: TSG HR        H07 0415 
   Revision: --------    Serial number: --------------
   Coding: 010802200001000000
   Shop #: WSC 00046 000 00000
   VCID: 50A51F390316F704D3-8004

No fault code found.

End-------------------------(Elapsed Time: 02:57)--------------------------

Any ideas?

 

[siLc]

Are all the installation tolerances of the new clutch pack within spec?

 

[DGMotors]

Are all the installation tolerances of the new clutch pack within spec?

on the double check they were 0.5 and 0.55 mm

 

[siLc]

Full disclosure, I haven't done a clutch pack swap myself, but simply am repeating the basics learned from the various more or less official videos on Youtube. If the engagement bearing shims are correct and the tolerances are measured good, then I'd have a look at the box's measurement blocks. Perhaps some measurement is out of normal range, which is preventing basic settings?

Run this through Google Translate, perhaps it can help -> https://www.drive2.com/l/538296979654967321/

 

[Dana]

I don't have much to contribute but

Field 1
4 = Basic Settings was canceled because
- Preconditions not met, engine rpm is too low.

253 = Basic Settings was canceled because
- Mechatronics is in Basic Settings

Field 2
4, 8, 12 = Basic Settings was canceled because:
- Pressure build-up faulty

I believe 19 =Basic Settings was canceled because:
- Clutch travel not within specified range.

Field 3 is unknown to me but someone else may be able to help with the 126 .

 

[siLc]

You might also want to check the MVBs whether the mechatronic is maintaining the hydraulic pressure needed for operation (45-60bar). Though if it wasn't, you'd have an appropriate fault code.

 

[DGMotors]

The pressure build up is very good and holds pressure better than most 7 speeds Ive done, Pump has to run every 3 minutes to keep up pressure

Now speaking to the customer the story has more to it,
He took the car and had it remapped and when he left the clutch was slipping badly, They took it straight back and tuner removed the map and supposed to have put the car back to standard map - this is why the clutch started slipping.
I have checked all the readings and the engine speed in the mechatronics doesn't exactly match the engine RPM from the engine ECU - Im not sure if this is the problem or not?
seems to be 25rpm out at 1000rpm and about 50RPM out at 2000rpm

Time    G641    G28 (From CAN)
29.54    1072    1096
30.01    1075    1099
30.45    1075    1100
30.91    1079    1103
31.35    1077    1102
31.81    1080    1104
32.26    1073    1099
32.72    1065    1092
33.17    1071    1094
33.62    1064    1090
34.06    1064    1089
34.49    1070    1093
34.94    1064    1089
35.41    1064    1089
35.83    1061    1085
36.3    1058    1082
36.74    1057    1081
37.19    1060    1084
37.62    1057    1082
38.1    1050    1074
38.54    1050    1073
39        1041    1066
39.46    1039    1063
39.89    1043    1066
40.33    1033    1057
40.77    1053    1076
41.2    1086    1111
41.65    1144    1167
42.12    1248    1275
42.55    1297    1326
43        1286    1315
43.43    1318    1347
43.9    1365    1395
44.32    1382    1414
44.75    1381    1412
45.21    1406    1436
45.66    1447    1480
46.09    1481    1514
46.55    1536    1571
47        1605    1641
47.45    1681    1717
47.91    1757    1795
48.34    1815    1855
48.77    1872    1915
49.23    1937    1979
49.68    2005    2050
50.15    2072    2118
50.59    1973    2022
51.04    1838    1883
51.47    1721    1765
51.9    1664    1703
52.36    1669    1706
52.79    1751    1790
53.26    1843    1884
53.7    1922    1965
54.16    1992    2037
54.59    2052    2099
55.06    2103    2149

We also have a 1.2 tsi beetle with 0AM gearbox and on this the 2 figures match perfectly
We have checked the teeth on the flywheel and both have 129

 

[Jack@European_Parts]

FOD WINS AGAIN!

SOME SLIPPING HUH?

IS THE TCU FIRMWARE CORRECT TOO?

 

[DGMotors]

The TCU software appears to be correct but I did update it to make sure,
The strange thing I've found is every saved scan we have for an 0AM gearbox has got gearbox coding of 0000020 but this car has 0000016 (I've checked over 20 cars now)

We changed the coding to 0000020 and now the basic setting go past the start engine phase and just completed with 254 0 0

We will put the car back together tomorrow and see how it drives

 

[Dana]

Ohh, neat. The 02E supported a debugging mode and long story short that was activated via Coding (after a diagnostic mode change). I wonder if the tuner enabled something similar and didn't change it back?

I also checked the SW# and SWL as well and it looked good but I did NOT notice the coding. Do keep us posted!

 

[Jack@European_Parts]

Like I said FOD...............