What You Will Read in This Article:

  • Gearbox types
  • What is GEARBOX TUNING Software? What do we use one?
  • How to do GEARBOX TUNING/ TCU REMAPPING
  • The Advantages and Disadvantages of GEARBOX TUNING/ TCU REMAP
  • Gearbox TUNING Software
  • Gearbox TUNING in ECU Training

Gearbox Types:

Gearbox systems are generally divided into four main categories:

1. Manual Transmission System (MT):
In this system, the driver disconnects the transmission path by pressing the clutch. Manually shifting the gear, the driver then restores the power path by letting off the clutch pedal.

2. Automatic Transmission System (AT):
Such systems use hydraulic couplings (torque converters) instead of a clutch. The automatic transmission system also uses sun gear sets instead of simple or spiral gears to enable automatic gear-switching. An automatic transmission system is heavier and more complex, thus less efficient than a manual gearbox.
Let's name some automatic gearboxes with remapping customizability: The VAG Tiptronic, G-Tronic set on Mercedes Benz; The 8-speed ZF gearbox or ZF 8HP used in the BMW X Series; The ZF 9HP in BMW, Chrysler, Dodge, Alfa Romeo, Audi, Jaguar, and Land Rover.

3. Dual-Clutch Power Transmission (DCT) or Semi-Automatic Transmission Systems:
Such systems take advantage of both manual and automatic systems' merits. However, they are highly costly and have a too complicated design, so they are mostly used in sports cars. Dual-clutch power transmission (DCT) or semi-automatic transmission systems use driver-operated electrical sensors and switching to switch gears.
These cars have DCT gearboxes with customizable remapping: The DKG gearbox in BMW, Audi S-Tronic, VAG in VAG models; PDK in Porsche; The Powershift system in Ford; and 7G-DCT in Mercedes.

4. Continuous Variable Transmission (CVT):
Continuous variable transmission excludes gear communication and is a perfect alternative to discrete gears. In fact, CVT systems use infinite varying speed ratios to achieve optimal engine performance in different working conditions. Today, most American and Japanese cars, such as Ford, Nissan, Fiat, Mitsubishi, Chrysler, Lexus, Honda, and Subaru. These manufacturers aim to improve these systems' efficiency. There are many types of CVT systems, including pulley-based systems, toroidal, continuous hydrostatic, variomatic (belt), and BorgWarner.

Multitronic, E-CVT, and CVT Xtronic are common types of CVT gearboxes with gearbox remapping capability.

hydroulic Automatic Gearbox- CVT Automatic Gearbox- Dual Clutch Automatic Gearbox- DCT Automatic Gearbox-
Torque Converter Automatic Gearbox                                                                                CVT Automatic Gearbox                                                                                Dual Clutch Automatic Gearbox   

 

What is TCU Tuning? What is The Purpose of TCU Tuning?

Most vehicles with automatic gearboxes are equipped with a TCU or Transmission Control Unit. In these vehicles, TCU has a variety of tasks, including gear shifting and torque limitation. TCU is connected to EMS to ensure overall better performance.
Just as we can tune ECU and apply our desired modifications, TCU is also tunable, a process called Gearbox Tuning. Gearbox tuning brings many positive changes, including higher acceleration and power. In the following lines, we further address these changes.

How to do Gearbox/ TCU Tuning?

Gearbox tuning is a software process done via the OBD port, just like ECU remapping. One of the advantages of the software method is that in some vehicles, two separate processors control the gearbox's performance, and the tuning is actually applied to these processors using the software method.
Besides, in some vehicles with replaced gearbox, tuning is preferred since the ECU needs the exact engine speed and gear ratio to detect the gear position. Usually, gear shifting disrupts the gear ratio, and that is why tuning is essential for fixing this problem. Gearbox tuning helps remove the incompatibility issues between the new gearbox and the ECU and improves the gearbox and vehicle's performance. 

Advantages of Gearbox Tuning:

The positive changes as a result of gearbox tuning are very tangible:

  • Increase in gear shifting speed (rate)
  • Removing the inherent electronic delays of gearboxes
  • Ability to increase or remove cut-offs
  • Improvement in shift points in “D” for upshift and downshift
  • Torque limit Removal
  • Better reverse gear shifting in automatic gearboxes (which is a function of throttle reaction)
  • Improvement in vehicle acceleration
  • More pleasure driving sense
  • Decrease fuel efficiency
  • Better car launch control
  • Modification and improvement of gear shifting patterns
  • Tuned vehicles have a higher clutch clamping force 
  • Full Manual Mode
  • Kick down Delete
  • Free Shift in Manual Mode

🚨The TCU is synched with the ECU, and these two units work together compatibly. So, if you are tuning your engine and remapping your car's ECU, you better remap the TCU s well because some gearboxes have torque limits; when the engine torque increases, these limits prevent torque transmission.
🚨Torque limits are a pretty common issue in DSG gearboxes (Direct Shift Gearbox), which are used on Audi, Seat, Skoda, and VW. Let's learn how DSG works: A Direct Shift Gearbox automates two separate "manual" gearboxes (and clutches) contained within one housing and working as one unit. DSGs have great software tuning potential, and are electronically controlled by Temic Controllers, and have the following generations available:

  • DQ200
  • DQ250
  • DQ380
  • DQ500
  • DQ511
  • DL501

DSG ECU Remap Option:

  • Increased RPM Limiter
  • Increased Shift speed
  • Increased maximum Torque
  • Launch Control
  • Kick Down delete
TCU remapping software-TCU remapping tools-TCU remapping cable-kick down switch digram
TCU remapping software                                                            TCU remapping tools                                                       TCU remapping cable                                                      kick down switch digram 

Disadvantages of Gearbox Tuning:

You cannot really name any particular disadvantage for gearbox tuning. Perhaps the only important point is that you should let skilled trustworthy tuners tune your vehicles because you cannot apply the same methods and use the same tools for all gearboxes, such as Manual gearboxes, CVT, DCT types (such as DSG, DKG, Powershift, 7G-DCT, S-Tronic), G-Tronic.

TCU/ Gearbox Cost By Remap?

TCU/ gearbox tuning price differs from cars and in CaracalTech we can do it for you with the lowest price and we do our best with guarantee and support.
Here, you can learn once, fully and for good, the adjustments or remap for TCU. Below is a link of TCU tuning training video in various software's and ECUs.

1- If you want to learn how to TCU remapping in WinOLS and ECM Titanium Software, you can enter to our ECU Training Course.

2- If you need only TCU remapping file, upload original ECU file in Tuning File Service, after short time our experts send you remapped file.

3- If you know remapping software like WinOLS or ECM Titanium, for ease and accuracy of work you can use CaracalTech Mappack in the following link.

📍For more information and probable problems feel free to contact us: support@caracaltech.com