changing an automatic gearbox

[billg]

I have a Superb 05 tdi the automatic gearbox pact in about five weeks ago .

Found a replacement on the net that cost £800 delivered. It came out of the same car with the same code(ZF5hp-19) EYF but it's 2008 model.

My mechanic has fitted it and there is no engagement with the engine whatsoever.

Could there be any difference in the boxes even if all the codes match up ? Has anyone else changed an EYF gearbox?

[Gaz]

Hello Bill 

 

Sorry to hear of your gearbox woes.

 

Can you be more specific when you say 'no engagement'.  Do you mean there's a problem with the physical coupling of the torque converter to the flywheel, or do you mean everything's joined up and you have no drive?

 

Are the selector linkages all connected up?

 

When the brake pedal is pressed and the lock light goes out, can you move the selector out of Park?

 

I'd imagine if it's a known good box, then it's probably something simple.  I'd think the gearbox needs telling it's got a new car, and the car needs telling it's got a new gearbox.  There may be other software or ECU changes that have happened between 2005 and 2008 which will affect it.

 

If if were me, I'd start with getting it scanned for codes on VCDS to see what that flags up.  My last gearbox work was on a Saab and that had to go to an autobox specialist before sufficient information could be gleaned from the box as to what the fault was.

 

Not much help.  Hope you get it sorted.

 

Gaz 

[billg]

Thanks gaz.

My machanic is baffled with it he's going to swap over the torque converter and see if it's anything mechanical to start with.

How should I go about getting the two to work together by the ECU?

[Gaz]

Wish I knew - I put my dunce cap on when people start talking about ECU's 

 

It's a job for someone with diagnostics and software skills.

 

Gaz

 

NB: bit of interesting reading here:

http://forums.tdiclub.com/showthread.php?t=379182&page=3

[jimbof]

If you log onto the SKODA ERWIN website ( https://erwin.skoda-auto.cz/erwin/showHome.do ) and buy an hour's time you should be able to download the factory manual for the gearbox (01V).

 

There is a section in it "3. Frequent causes of damage".

First item is "All gears without shaft grip" which sounds a bit like what you describe.

 

Possible damage:
Driver at ATF pump gear is broken off.

 

All the causes are due to incorrect assembly of the gearbox onto the car (missing spacers, torque converter not fully inserted, etc)

 

Anyhow, I'd suggest that getting that document will be the best £5 you ever spend... 258 pages of info you'll struggle to get anywhere else.  You can download all the manuals for the car in that time, and then you have them forever.  If you have a phone with a PDF reader, you then have the world's smallest factory manual!

 

Note I've never had one of these in or out (nor do I ever intend to!) ; just reading the above from the doc.

[oh_superb]

IMO it sounds like your mechanic has either messed up (can happen to the most experienced) or the box was not really as good as advertised!

[billg]

Just a thought , is it possible that when zf produced the box for 2008 they changed something that isn't compatible with 2005

The valve body or torque converter or inner wiring and if so how on earth do you go about finding this out?

[jimbof]

Partsbase would indicate not:

http://www.partsbase.org/skoda/superb-sup-eu-2008-3u-8-000-001-30050-gearbox-complete-5-speed-automatic-gearbox/

http://www.partsbase.org/skoda/superb-sup-eu-2008-3u-8-000-001-32160-converter-valve-body-for-5-speed-automatic-gearbox/

Torque converter and valve body part numbers remain constant over the whole age range it seems, without any specifiers for VIN number or gearbox number.

Damaging the part mentioned in that doc is quite a well known issue, I had seen it mentioned in a few places.

Not sure I would trust gearbox work to a general mechanic. I had mine rebuilt at a specialist and there were still two issues; I had a thump going 1st to 2nd, which they sorted, and they left the exhaust misaligned which took 3 mechanics to work out why I was getting a clunk on acceleration.

But you are there already now, so the best you can do is get the doc if he doesn't already have it, and check the obvious issues they list. It is an unusual doc - the VW manuals don't usually have much of a fault finding section - must be there for a reason...!

[jimbof]

Also, if you do get the docs for the gearbox, there are some additional docs that don't get listed for Superb but still apply, which are listed under 3B Passat (fault finding via diagnostics, etc).

From what I know there isn't anyone on the Superb Briskoda forum regularly who has been intimate with this gearbox. There is one guy over on the B5.5 UKPassats forum who has done a strip / rebuild himself.

[billg]

Thanks all , the ATF gear pump lugs have snapped off! mechanic says the torque converter has probably been banged about in transit as it wasn't secured to the box in situ properly.

Oh my life!

[Gaz]

Cripes!!    :'(

 

Gaz

[rotodiesel]

There are differences between the 1.9 and 2.0 PD engines in terms of gearbox engagement with the engine. I have no interest or detailed knowledge of the autos (not suitable for my job) but I do know that there are problems interchanging the manual transmissions.

 

Some misguided people wish to fit 6 speed manual transmissions to 1.9 engines and when this job is attempted there are problems with spigot bearing engagement and starter engagement mesh distances. Of course, for an engine speed difference of 120 rpm in top gear at 70 mph (GGB transmission), there's no earthly point in doing it and the 6 speed unit is less robust than the 5 and has a crappy linkage. The fashion conscious could just fit the gear knob with a lot less bother...

 

Interchanging VAG parts between differing series always presents difficulties unless you have really detailed knowledge. If the above applies to your job, the drive lugs snapped off because they were not fully engaged. EKTA is your friend here.

 

rotodiesel.

[jimbof]

There is a big "gotcha" mentioned in the book - mis-installing the torque converter causes this issue.  They specify the correct and incorrect measurements between the torque converter and the converter bell.  That they mention the two measurements makes me think it is a common (and expensive) mistake.