Another D2 S8 with Auto Transmission problems - ZF 5HP24A Strip down photos
 

Hello all,

Some of you may have seen my post in 'Introductions' about S8YOT's old S8 which I bought last night.

Well it's done 183K, had an oil change at 100K and has died within the last 500 miles or so.

From what S8YOT told me, it left him working well.

The dealer I bought it from had sold the car to someone else and on the delivery drive (by a now jobless delivery driver!), the gearbox let go and now has the follow problems.

Put it in D, you try to set off and nothing happens.. then BANG! and you're in. Then you're not and then it goes into Limp mode.

Once on the move, you can clear the faults and if you're at a speed which would be in 5th, it works fine and is happy. However, if you boot it and it drops to 3rd, you're into problems again.

There were two fault codes on it when I first plugged in:

17116 - Gear 2, P0732 - 35 - 00 - Incorrect Ratio
17114 - Gear Ratio Monitoring, P0730 - 35 - 00 Incorrect Ratio

After each time it went into Limp mode, only 17114 came back.

I've done a small bit of research regarding the ZF 5HP24 and in all the vehicles that it was fitted to, it has problems!

I bought the car with the intention of breaking it and running the engine in one of my projects.. this may still happen but I want to get it working fully again first.

I'm going to look into carrying out the repairs myself. I'm a Porsche trained technician who has also worked for Audi/VW specialists so know my way around a car. The only areas I've never gone into are Auto Transmissions. I rebuild my own manual gearboxes and have all the associated tools for that.

Because there are so many problems with the ZF 5HP24, the issues are well documented along with fixes.

This will be one interesting and steep learning curve :D

The biggest issue I have at present is finding somewhere to take the gearbox out and then store the car while I fix it.

MG

If you want to have a go, hit quattroworld and look for TozoM8's threads.. He's THE gearbox guy :)

Update:

I took lunch time today to wizz (!) around the corner to my friendly garage who are happy to lend me their 4 post ramp, plugged in, got it up to temp, took out the filling plug and nothing came out!

Ok, so I start filling... I think it took between 1 and 1 1/2 litres (taking time to run it through the gears as per filling procedure).

It made no difference :(

Ho-hum... wishful thinking but it was worth a try.

So I'll be pulling the box out and rebuilding it.

Chester Transmission are going to be supplying the parts and some pointers as to where to look apart from the obvious stuff.

I'll keep you all updated as I go along. I'll be pulling the transmission out over a weekend so that I have time to get everything undone which won't have been touched for the last 11 years!

MG

Good luck, I hope you manage to rebuild it for cheap, that would be good news for the rest of us.
I'm really curious to see what made it fail.

I'll be watching this one too.

I've left mine to get oil drained and filter this weekend but it's only done 107k was hunting a little. Due to dirty filter I reckon for sure causing low oil pressure the box. will let u know updates. Changing oil at 20k seems the way to go with these d2s. 150 parts each time is a pain but there you go. If nothing else changing oil will add at least some extra miles out the box I hope.

Doing engine oil 10w/4o semi and oil filter at same time, will drop it 10k anyway and change it again so10w/40 will be ok for me. Full synth for people who run longer without changes.

Just rocker cover gasket left for me to do then im having a break from d2 repairs and changing the stereo etc.

Ill prob go for a s-class next I got an a4 too I'm all vagged out.

Not happened to mine, but I'm still watching this thread with a great deal of interest...
Good luck chap :)

R
 

If you manage to do it you'll have about 30 8s outside youR house waiting........+++

Well I managed to grab an extra long lunch break today and changed the oil and filter. No change with the problems :Confused:

http://i690.photobucket.com/albums/v...a/IMAG0279.jpg

http://i690.photobucket.com/albums/v...a/IMAG0281.jpg

Interesting that you can see one of the drums from underneath. No damage to it and nothing interesting in the sump. The Magnets needed cleaning but no chunks of metal etc. Most uninteresting!

http://i690.photobucket.com/albums/v...a/IMAG0280.jpg

http://i690.photobucket.com/albums/v...a/IMAG0282.jpg

All buttoned back up, quick test drive... no difference so it's coming out on Friday morning and then I'll strip it down over Easter weekend.

I'll keep the photos coming.

MG

The force Is strong with this one!