The brief
A Cross Polo 1.2 came in with the gearbox misbehaving, shifting problems and the odd skipped gear, the kind of thing that's a cause for concern because it doesn't fix itself and only gets worse. The transmission, this one a DSG, wears over the years from the heat and the load it lives with. Burning smells, leaks, a worn clutch, all signs the box is past its best. By the time it's slipping and skipping gears, a fluid change alone won't bring it back, the box has to come out, get stripped, and have the worn parts renewed, an overhaul, with the double clutch assembly and the worn components replaced.
The diagnosis
Careful inspection with the diagnostic equipment confirmed the box was in a bad way, the conditions called for an overhaul. With the gearbox dismantled, the worn sprockets inside were exposed, along with extensive wear and tear, so the double clutch assembly and all the relatively worn parts needed replacing. That's a full gearbox overhaul, the worn sprockets, the double clutch assembly and the worn parts renewed, plus fresh fluid, rather than a fluid change that wouldn't touch the worn hardware.
The work
The gearbox was dismantled from the Cross Polo and stripped to its components, every part cleaned and measured, and the worn sprockets, the double clutch assembly, the seals and the relatively worn parts renewed with genuine VW-spec parts. The box was reassembled with care, refitted, and filled with the correct DSG fluid to the right level at the right temperature, the way it wants it. The adaptations were reset so it relearns its shift points on fresh fluid and clean hardware. A road test confirmed smooth, prompt shifts up and down, no slip, no skipped gears, and the box behaving as it should.
The outcome
Smooth, prompt shifts through the whole range, no slip, no skipped gears, fresh fluid, and a gearbox that drives the way it should. The Cross Polo went home with the box overhauled and shifting properly. By the time a DSG is slipping and skipping gears it needs the worn parts renewed, so a proper overhaul rather than a quick fix is what gets the gearbox back, done once and right.
