The six-speed DSG gearbox, which was introduced in 2003, uses a pair of clutches submerged in oil. The new seven-speed gearbox adopts a pair of dry, organic bonded friction linings that do not require cooling, making the drivetrain more efficient through the extra ratio and the fact that less power is required for the gear selection and clutch servo system.

For the first time the DSG gearbox has been mounted transversely. Measuring only 369 mm in length and weighing only 79 kg including the dual-mass flywheel the gearbox is remarkably compact. These modest proportions mean it can be applied to models from the Polo right up to the Passat.

In adopting seven-speeds, Volkswagen engineers were able to lower first gear to improve acceleration from a standstill. By contrast seventh gear has been raised to act as an overdrive function making it ideal for motorway driving with the additional effect of raising economy and comfort levels.

The volume of oil contained within the gearbox has also been reduced by 75 per cent. The oil circuits are split into two in an effort to protect the lubrication’s purity. As with a conventional manual gearbox, one of the circuits is used for cooling and lubrication of the gear teeth, the second feeds oil to the gear actuators. Since the clutch does not require cooling the quantity of oil was reduced from seven litres in the six-speed DSG gearbox to only 1.7-litres in the new seven-speed system.

Production of the gearbox is set to start at the end of the year with its first application believed to be planned for the Golf and mated to the 1.4-litre TSI petrol and 1.9-litre TDI diesel engines.

New TSI To Replace Existing 1.6 litre FSI Unit in Europe

Volkswagen is also introducing a new turbocharged 1.4-litre engine to replace the existing 1.6-litre FSI engine. Based on the 1.4-litre TSI engine the new unit is not fitted with a supercharger and instead uses a sophisticated turbocharger. The result is an output of 122 PS linked to a choice of manual or DSG gearboxes.

The new engine is planned to be fitted to the Golf, Golf Plus, Golf Estate, Jetta and Passat models, replacing the current 1.6-litre FSI engine when production commences later this year.