The DQ200 (internal designation: 0AM) is a direct-shift gearbox for smaller cars from the VAG group. It has a reputation for not being particularly reliable with expensive repairs waiting to happen. But with some preventive maintenance this gearbox can last hundreds of thousands of kilometers and outlive the rest of the car.
The gearbox has two oil circuits. One for the gears and another one for the mechatronics (hydraulic oil). The manufacturer does not provide for any maintenance on the component. Nevertheless, it is good practice to change the oil(s) regularly.
- Gearbox oil: Change every 60 – 100 thousand km
- Mechatronics: Change every 8-10 years.
This is my personal schedule for our 2011 VW Polo V 1.2 TSI. It is actually not a lot of work and the improvements are noticeable. Afterwards the gear shifts are quieter and smoother.
What You Will Need
- 1.7 liters
VAG G 052 171SAE 70W – 75 transmission fluid - 0.9 liters
G 004 000hydraulics fluid (some sources call for 1 liter) – if you intend to change it as well
Alternatively, you could get a kit with all fluids, a new drain plug and two venting nozzles included. But after using one of those, I found that the additional parts are not really required.
- Socket wrench with various extensions
- hoses in various diameters
- A dedicated gearbox fluid filling device can come in handy
- But I have seen people using just a funnel or filling it directly from the bottle.
- Oil drain pan
Let’s Start
Raise the front of the car.
Or the whole car, if you have a car lift.
Remove the starter battery and the battery tray.
Disconnect negative first (black), then the positive (red). There are several screws holding the tray down. The rest just pops out.
If you are changing the hydraulics fluid, remove the starter.
The filling nozzle for the hydraulics fluid is underneath the starter. I have seen people using the forward facing venting nozzle for filling. But this didn’t work for me. You need to remove the electric connector to be able to access one of the screws. I needed a flexible extension for this.
Remove the panels under the car.
Remove the drain plug for the transmission fluid and drain it into a pan.
It’s the bigger one towards the back of the car.
Remove the drain plug of the mechatronics and drain the hydraulics fluid into a pan.
It’s the smaller plug towards the front of the car.
Close the drain hole for the transmission fluid.
Tighten with 40 Nm.
Close the drain hole for the mechatronics.
Tighten with 5 Nm + turn additional 90°.
Fill 1.7 liters of transmission fluid into the rear venting nozzle.
You need to remove the black cap and then attach a small diameter hose either into the nozzle or a bigger hose over it. In my pictures, you see the latter variant. This will take a while as air will come out as you try to fill in the fluid. Re-attach the small black cap onto the breather nozzle when done.
Unscrew the oil filler plug for the mechatronic.
It’s the small one towards the front of the car. You have to remove the starter to access it.
Fill in 0.9 liters of hydraulics oil.
Some sources say 1 liter. Use a small hose or funnel.
Put everything together
Put everything back together.
Lower panels, starter, plug, all hoses, battery tray and battery.
Go for a test drive and check for any leaks. It should shift much smoother now.
