2.5 TDI AUTO TRANS thread

[Greg Roles]

For reference to all these solenoids and directions, here's how the valve body sits in the car. If you print this pic out and hold it over your head, that's what you see with the pan off.

[BrianJ]

Very impressive write-up. The findings of the deteriorated cables is most interesting.

If its worth anything, I was told that when any piston bore becomes worn that the oil pressure is lowed due to the leakage, and this can effect the entire operation. I am not sure about this theory as I think the oil pressure is only applied by a solenoid during shifting.

I am following this with interest.

[Greg Roles]

Very impressive write-up. The findings of the deteriorated cables is most interesting.

If its worth anything, I was told that when any piston bore becomes worn that the oil pressure is lowed due to the leakage, and this can effect the entire operation. I am not sure about this theory as I think the oil pressure is only applied by a solenoid during shifting.

I am following this with interest.

Yeah, cause I reckon half the issue the old PD injector failures had was a hardened and cracked loom sitting in hot engine oil. Seems to me if these solenoids have to be within a particular resistance range, triggering them with a terribly cracked and bundled together loom in hot ATF is only adding to potential issues. I'm actually amazed my box was even working, the gaps and potential for wires to contact is that bad...I'll get some pics.

I'm in the middle of the shift kit, and have this arvo to crack on and get the rest done. I'll have a look at my valve bores too, thanks for the tip, will clean out the ATF properly and look for play.

[Greg Roles]

Wow, I see now why auto rebuilds cost serious cash, took me all arvo to install the shift kit in just the valve body, but it is a fairly complex bit of kit to pull apart for a first timer like me. The Transgo shift kit kit is exceptional, and the instructions are simply glorious.



I found one solenoid different ( older?? ) than the rest, and half of them were quite sticky. "Drilling" them out ( all long drill, see instructions below) was easy, and I don't really feel I actually removed much, getting them clean and the piston dropping out was a bigger thing. I just hand filed all the end caps off, you don't keep the stock "coin" end piece at all, so you can go a 2nd cut or rougher on the filing to get them off. Some were a bit tricky.

What the instructions don't point out, well perhaps they do somewhere, but when turning the drill by hand, remember to actually push the solenoid innards open with the drill, so you actually ream the whole "canal". Didn't discover this till my second one, so the first one only got a 3/4 drill ream before I sealed it all back up as I didn't push hard on the drill.

A STRONG small magnet is essential for getting retaining pins and plunger keys out, as is a few dental type pics, some cotton buds to clean things, some sort of cleaner spray ( I used WD40 ) and a micro drill chuck. The supplied drills are TINY, and I wrapped a little electrical tape around them and drilled carefully with a normal drill, wasn't ideal but got me there, but you really need to order a microdrill chuck from Jaycar or somewhere. Be gentle as the smaller two drills are TINY and would break real easy, plus the size obviously matters and is imperial. It;s a complex thing to pull apart, especially the main part, as there are pistons, tiny plastic check valves and a blaa bearing that can fall out of each "Clam" shell half when you split the main section. Thankfully the instructions are comprehensive, so they were a massive help. I would suggest leaving yourself a lot of time, have a lot of rags on hand ( ATF keeps coming out every section split, and I'd avoid drinking, your brain needs to be on high alert!!

[Greg Roles]

And for future reference, this kit is SO worth it, had to buy it through Amazon from memory as only they would ship to Australia, but I'm sure you could use myUS shipping forwarder or similar in a pinch too....

[Greg Roles]

[Greg Roles]

I'm sure I will smell like ATF for the next few days, Jesus, my hands are flogged!

Valve body reassembled for reference to all the sections in the instructions!

[Greg Roles]

...and a great video on the job by a guy with a few O9G videos which I will be watching a few times no doubt!!

09G Valve Body TransGo Shift Kit Intall - Transmission Repair - YouTube

[Greg Roles]

The penultimate video on the O9 auto boxes, an internal webinar for the Auto rebuild industry. Shows how to vac test for valve body wear, clutch wear, and even just readapting the box has three distinct steps and a lot of test driving etc. I bet most places don't bother with all this readapting...but a must watch for info!

09G Internal Webinar - 8/8/17 - YouTube

[Sunny43.5]

Very impressive write-up. The findings of the deteriorated cables is most interesting.

If its worth anything, I was told that when any piston bore becomes worn that the oil pressure is lowed due to the leakage, and this can effect the entire operation. I am not sure about this theory as I think the oil pressure is only applied by a solenoid during shifting.

I am following this with interest.

Not only that which you explained but also blocked filter will also lead to failure as was the case with ours .