It is not unexpected. It was something that was bound to happen and just about every mass manufacturing automotive company has to go through this issue.

I've said it before, I think in their drive to become the world no.1 automotive manufacturer, their quality have taken a dip. It might not be directly their fault, might be with their suppliers in trying to keep up with demand, certain steps of QC were skipped in order to meet timely demand.

Put it this way. Technology has a curve that companies need to overcome. Toyota has invested heavily into hybrids, while VW has done other stuff. If nobody innovates, then basically it becomes a refinement and enhancement of existing technology and the Japanese have done just that with their cars. Not very interesting at all is it?

Every subsequent generation will improve upon the previous generation to give a better product. And it is always the bystanders that gains from the innovators mistakes and drawbacks, DSG gearbox is no exception to this rule.

We know that for better fuel efficiency and emissions then dual clutch is the way of the future. The question is - is it an inherent design flaw with VW DSG design or component problem? Whatever it is, it is a hurdle that manufacturers need to overcome and there's only so much data you can gather in a simulated environment.

If it isn't VW then it would be someone else. It's unfortunate but it is a process which they have to go through in order to improve upon existing designs.

The top 5 positions are dominated by VW, GM, Toyota, Ford and Hyundai. But look at the gap between Toyota and Hyundai and then Hyundai and Ford. That's how much numbers these manufacturers are pushing.

0.05% defect rate for Hyundai is definitely not the same number as 0.05% defect rate for Toyota or VW.