2/17/24, 10:38 AM DQ-250 Gearbox – United Tuning Performance Indonesia

DQ-250 Gearbox
VAG ECU & DSG Tuning Specialist

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DQ-250 Gearbox

DQ-250 Gearbox
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Models: All VAG Models built from 2003.

Mainly 2.0 and 3.2 V6 Engines

The DQ250 gearbox, also called the 02E, is the first DSG gearbox from Volkswagen. This was started
in 2003 and has hardly been modified to date. This gearbox is known as strong and reliable.

With TVS / DSG software the DQ250 can be used up to 600 BHp / 650 Nm!!

Tuning Stage Driveability Max Torque Note

Drivability upgrade yes 350 Nm –

Tuning stage I no 410 Nm –

Tuning stage II no 500 Nm –

Tuning stage II + yes 500 Nm Most options activated

Tuning stage III yes 580 Nm All options

Tuning stage IV yes 750 Nm Race Clutch

Here are explanation on each stage DQ-250. Please Feel free to contact us for more further
discussions:


reza@utpmotorsport.com (WA: 08158959988)

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henry@utpmotorsport.com (WA: 081279770070)

1. Drivability upgrade
TVS-engineering started programming DSG’s in 2006 and now programs +/- 2.000 DSG’s in its
main workshop in The Netherlands.
It all started with modifying the D mode(drive) and the S mode (sports). This may look simple but
it is way more complex as most people think. In 2006 we had our customers returning too often,
because the gearbox always showed problems. Like delay between 2 gears, or unwanted
downshifts. Nowadays we see more companies “trying” to alter the D and S mode, in a very
simple and poor way. Please understand that the shifting maps that we sell, are based on 10
years of experience. Example 1: Golf6 R20/S3 These models suffer from poor shifting programs.
In “D” drive mode the gearbox shifts up too early to 4-5-6th gear. As these cars are equipped with
the larger K04 Turbo, which have more turbo lag, a not ideal driving situation is created. With our
modified shift program, the turbo response is much better. Corner out-accelerating is further
improved as the gearbox already downshifts before entering the corner, instead of when exiting
the corner. The S mode is exactly the opposite, it is way too aggressive. Steady cruising in S mode
is hardly possible, because the gearbox stays in low gears 3 and 4th. Example 2: 2009+ 2.0 TDI
140-190hp To meet the latest emission norms, car manufacturers are forced to program their
gearboxes in a very poor way. It results in shortened lifetime, poor drivability, and irritating
droning and noises. TVS tries to improve the settings, and keep fuel consumption at the same
level. The result is: better drivability, less wear to the dual mass flywheel, less wear to the gearbox
and no droning at all.

2. With most TDI engine’s power drops above 4000rpm. Therefore, we program upshift in D and S to
4000rpm.Example 3: 2003+ 3.2LV6 R32 etc
About 50% of the Golf R32’s suffers from a problem when shifting from 5th to 6th gear in D mode,
at about 40-60km/h. This is noticeable on a smooth road. Accelerate with very low throttle, listen
carefully (radio off). It is important to upgrade the DSG software in an early stage, or prevent
getting it to happen by re-programing the DSG before the symptoms are noticeable.
These R32’s also suffer from “clunk” noises, mostly on downshifts. This is caused by poor
synchronisation from synchromesh-rings. Modification of the DSG software is needed to avoid
wear of the rings.
In “D” drive mode the gearbox shifts up too early to 4-5-6th gear, all solved with our special DSG
software.

3. Stage I tuning up to 410 Nm

Stage I is for low-budget customers.
Torque limiter is set to 410Nm. No more, no less.

Factory DSG torque limiter is set to 350Nm at most DQ250 files.Be carefully not to be misled by

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common misunderstandings. Above 410Nm more modifications are needed to get sufficient oil
pressure, although on the dyno it looks like 460Nm can be reached by just modifying the torque
limiter. Please understand that a clutch is stressed most at peak torque, and in high
gears. Example: Golf6 GTI
On the dyno, in 5thth gear, the power curve looks OK because run at unloaded dyno. When you
drive it on the road, and do full throttle, the gearbox shifts at 6000-7000rpm. The clutch them
seems to hold as well. But when you drive it on the highway, with high oil temperatures, AND you
shift at +/- 4000-4500rpm (where maximum torque is) the shift takes 1 second instead of
0,2seconds. This causes severe temperature increase, and clutch wear.This will NOT happen at a
full throttle shift at 7000rpm, because the torque-level of the engine already has dropped at that
high rpm.
Common Golf Mk6/7 GTI/R and A3/S3 8V problem:
We see an overload of faulty tuned cars, which are reprogrammed by respectable companies.
Results: The clutch slips. The slip is mostly noticeable at +/-3000rpm when the turbo “kicks in”.
This is caused by a combination of wrong engine tuning and DSG tuning. Remove booth and
contact us a.s.a.p. Because clutch will wear out in the end.

4. Stage II tuning up to 510 Nm

Stage II is an affordable but full program, with all modifications included to get maximum
acceleration and engine power.
Our D/S Drivability upgrade is not included, if you want drivability upgrade please select our stage
II+ package.
Our unique Launch control mode is included, as well as the maximum rpm mod (for K04
upgrade’s etc).

1. Unique Launch control

When you drive in D/S/M TSI’s engines have the typical “prrr” noise on upshifts. Caused by
fuel cut-offs. This is a so called “torque reduction”.
When the DSG performs a Launch control. No torque reduction is performed mean while
the upshifts. The main goal from VW-Audi was to achieve a better 0-100km/h time.
This gives a lot of slip, stress and heat to the clutch. Which will result in clutch-wear and
more problems.
TVS offers a unique Launch control function with torque reduction (fuel cut-off) activated
and Variable RPM Launch Control depending on throttle input.
0-200 time may vary depends per model and hp/Nm.

2. Clutch Pressure increase

A DSG clutch is not ‘open’ or ‘closed’ pressure model.
The higher the torque, the higher the oil pressure which closes the clutch.
A common heard thing (on the forums) is : “my tuner increased the clutch pressure but it

had no result, so they said my clutch was faulty”.Well that can never be correct, because you

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cannot “increase clutch pressure”. The mechatronic calculates the needed clutch pressure by
(measuring) the actual engine torque AND clutch slip.
This calculated oil pressure varies every tenth of a second. Very rough indication (can vary
up to 2 bar):400 Nm = ca 10.5 bar
460 Nm = ca 12.5 bar
500 Nm = ca 14 bar(+other mods needed)
600 Nm = ca 18.5 bar(+other mods needed)Listing of most altered functions:
● Torque limiter raised – Clutch Pressure +/- 14 bar
● Torque capacity increased
● Less unwanted downshift on light acceleration
● Shifting Speed D+S+M upshift – Shifting Speed D+S+M downshift
● Engine breaking reduced (optional)
● Torque reduction delay D+S+M – Flippers/paddles reduced downshift time.
● Overall reduced flipper time response.
● Faster take-off 0-5km/h in D/S/M/LC.
● Improved clutch cooling
● Clutch temp. warning
● Max RPM D+S+M 4000-8400RPM
● Full manual control
● No kickdown in M
● No auto upshifts in M (optional)
● Unique launch control modus w/ torque red.
● LC maximum rpm
● LC rpm fully variable by throttle position
● Launch control response time
● Optimal base file used
● MFA gear display indicator
● Etc. (customer specific options)

5. Stage II+ tuning up to 510 Nm included drivability upgrade

Stage II+ is the most sold upgrade. Its combines all stage II tuning options and our drivability
upgrade. It is tested on cars with 525Nm but we advise 500Nm max.
Above 500Nm the Mechatronic outscales and cannot handle higher torque.

6. Stage III tuning up to 600 Nm

Up to today, TVS is the only company ‘worldwide’, who managed to crack the 500Nm limit. It is
very important to read the following information:Above 500Nm the Mechatronic ‘out of
scales’ and cannot handle any higher torque. TVS had to design a new clutch-pressure calculation
method in the software. Please understand this is NOT a standard remap procedure by raising
some bits & map table.Because every clutch and gearbox is a little different, the maximum 
transferable torque may vary. That means in real life: Stage II(+) DSG software can handle 510-520

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Nm. But with a worn out clutch it may start slipping at 480Nm.Do not compare our stage III
software with other software suppliers who offer 500+ Nm files
If another company offers a 500+ Nm file, you have a problem because it 99% proves their lack of
knowledge.
They do not perform full-throttle shifts at +/- 4000-4500rpm (where the maximum torque is), just
doing some dyno runs do not prove anything at all. In the end your clutch will slip more and more
and will rapidly wear out.These days TVS is not the only DSG software supplier anymore. Many
companies step in to this lucrative market. The big downside is their lack of knowledge due to the
‘steal-copy-paste’ methods, which are ‘standard’ in the chiptuning sector. Each time we re-tune a
DSG, we see the same wrong alterations in the mapping. These programming mistakes are copied
over and over and over again by tuners all over the world, including respectable large tuning
organizations.TVS repairs 2.000 DSG’s per year, and if all sub dealers are taken in to consideration,
then we program many thousands DSG’s per year. We see the drama from other tuning
companies every single day.

Example of the complexness of DSG software

We had a customer with a 620Nm strong mkV GTI with Turbo upgrade. It had DSG software +
Raceclutch on it from another software supplier. On the dyno it had 620Nm in 5th gear. On the
highway, in 6th gear, the rev-needle was fluctuating on full throttle, and shifts where very rough
now and then.
After a few weeks the clutch started slipping hard, from one day to another. The driver thought
his clutch was worn, because the software was unchanged.
The cause was a problem in the Software, not the clutch. It exceeded the 500 Nm range so all
calculations got screwed up. With our software all problems were gone and, more important, it is
stays good.

The stage III software spares the costs of an expensive race clutch (+/- €2000,-)

We tested this software on Golf6/Golf7 with K04 hybrid / Garrett / IHI up to 620Nm on stock
clutch, with up to 19 bars of oil clutch-pressure.
Above 525Nm and a 4-wheel drive application we always recommend a race clutch, TVS and HGP
supply the best clutches on the market (to our opinion).
The stage III software includes drivability maps that match the large turbo. The characteristics of
a Garrett turbo are completely different then an IHI turbo, so make sure to inform us about the
turbo that is used.

Listing of most altered functions:

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● All stage II options

● Modified torque calculations, op to 650 Nm
● Altered input signals CAN-BUS
● Firm clutch engagement on up/downshift
● Smooth shifting on easy driving
● Modified clutch K1->K2 crossover
● Oil Pressure up to 19bar

7. Stage IV tuning up to 750 Nm

Above 600Nm a race clutch is needed. Raising clutch-pressure is no more sufficient.
Above 525Nm and a 4-wheel drive application we always recommend a race clutch, TVS and HGP
supply the best clutches on the market (to our opinion). For race applications we always advice a
race clutch. Even if the car has just 400Nm. Simply because a race-clutch produces less heat-
peaks due the higher amount of friction plates. SSP/Dodson clutches use harder friction materials
which can withstand higher heat peaks.
The disadvantages of using these hard friction plates is that the DSG software cannot cooperate
with them under normal driving situations. They cause heavy vibrations and clutch judder. After a
very long drive-in period (1.000-3.000km) it should drive better, but this is not always the case.
Many years ago TVS pioneered in developing special software versions for the SSP clutch plates,
which were used in world’s fastest (street legal) GTI’s. They eliminate the long drive-in period as
well. Same for the Dodson clutch.The factory friction and steel plates are extremely high-tec and
durable. They can withstand extreme temperatures.
Fact: We see burned SSP/Dodson clutches every week. We hardly see any burned OEM clutches,
not even after lots of slipping.Listing of most altered functions:
● All stage III options
● Special mods for racing clutch
● Elimination of long drive-in / basic setting period. (reduced to 50km)
● LC drag racing mode (optional, may damage clutch)
● Altered input signals CAN-BUS

all explanations above are copyright from TVS Engineering

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