Clutch 02E 0B5 0BH 0BT solenoids repair (Audi Volkswagen Skoda Seat)

Now we will show how the mechatronics of 6 and 7-speed DSG solenoids are repaired. Concern VAG decided to unify some elements of the control units of its DSG transmissions and as a result we get a number of spare parts that are compatible with different transmissions, in particular solenoids that control the clutch fit to the following boxes:

• 02E (DQ250) - 6-speed automatic transmission with double wet clutch for front-wheel drive, can be found in almost the entire VAG model range  - on Audi A3, Q3, TT / Seat Leon, Toledo / SKODA Octavia, Superb / Volkswagen Caddy, Beetle, Golf, Jetta, Passat, Scirocco, Shara, Touran.
• 0B5 (DL501) - 7-speed automatic transmission with double wet clutch for rear and all-wheel drive. Appeared in 2008 on the Audi Q5, it is a logical development of the 02E and 0AM boxes. In addition to the Q5 it was installed on the Audi A4, A5, A6 and A7. The transmission was designed to transmit a large torque (up to 550 Nm at 9000 rpm), it was aggregated with engines from 2 liters.
• 0BT / 0BH (DQ500) - 7-speed automatic transmission with double wet clutch for front-wheel drive cars. Installed in different versions on Volkswagen Golf, Tiguan, Transporter as well as  Audi A3, Q3, RS3, TTRS.

So let`s proceed to the repair of the solenoid, we start, as always, with checking on the stand.

This is the stand for testing solenoids for performance. It allows you to test solenoids in different temperatures and allows you to choose different profiles. Despite the fact that  solenoids are the same and interchangeable - the boxes work differently, and the solenoid in 02E will work with a lower oil pressure compared to 0B5, therefore comprehensive testing is carried out

So we nstall the solenoid in the stand and test. The steps on the graph show the incorrect operation of the plunger.

Using a slightly upgraded wrench we disassemble the solenoid

Let`s take a closer look at the insides. First of all, we are interested in the state of the guide bushes, there are 2 of them in such solenoids, on both sides of the coil. The wearout of the internal diameter leads to jamming that we saw on the graph during testing. Sleeves will be replaced for new ones.

Carefully knock out sleeves using a special mandrel.

Next, we install new bushings. The bushings are split, they take the final diameter only after installation, the inner coating is polytetrafluoroethylene. We press them using a hand press.

In the photo below you can see  already installed new sleeve. Time to start assembly process.

Next, the insides of the solenoid are cleaned of dirt. During assembly, the master checks how the plunger works in the sleeves, sometimes it becomes necessary to quickly clean the inner surface of the sleeve with fine-grained emery paper. To close we use lathe chuck with cams suitable for this task .

After assembly, we check the solenoid on the stand. If the result is satisfactory, we can give it to the client or install it in the car.

Repair of  02E 0B5 0BT 0BH solenoids costs only $ 40 apiece, which is much cheaper than buying a new solenoid, while at the same time we give a guarantee for the work performed.

Any questions? The repair departmentwill advise on any technical issues:

Warsaw Repair department

• +48 799 920753 ​
• +48 574 515898 ​​