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| D2 - Transmission Gearboxes, diffs, drive shafts. |
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#1
2nd February 2011, 09:01 PM
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Pre-Facelift S8 Manual Conversion?
I own a pre-facelift S8 with a gearbox now stuck in limp home mode,
and unless it's something small like F125 switch, it's looking fairly likely it's time for a change - the car has 146k on it, 36k of which were mine, so she's well in the danger zone. I was wondering what is required to carry out the manual conversion? My car has the 32v AHC engine, the only conversions I've read about are in the states using 01E DSY Audi B5 S4/RS4 gearboxes, and on facelift 40v cars, so I know that it may not be indicative of what's to be done on a pre-facelift. As far as I know the manual in the Euro S8's was a 01E DGV gearbox, are there any other cars that had this box, maybe TDIs? I assume that a different driveshaft would be needed, would the stock S8 manual driveshaft be available form Audi? Pedal box, clutch cylinder, linkages would be necessary, would the same half shafts be ok? Does anyone have a parts list of what is necessary to carry out this conversion? 
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#2
2nd February 2011, 10:30 PM
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Tozo on quattroworld has just done a few manual D2 conversions but he is in the States. It's doable might be worth doing a search on there but please keep us updated on what you find/do. Also pics of your car are a must
__________________
2009 Audi RS 6 Saloon V10 - 420mm Ceramics, Keyless, Soft Close, Adaptive Cruise, Glass Sunroof, Blinds, Twin Pane & UV, Freeview & DAB, High Beam Assist, MTM bits, Audi Exclusive Bits, MRC, Milltek, GYEF1 ASY2's, Bluetooth streaming music to AMI mod - 753 PS/1021 NM 2016 Audi S3 Saloon, Sepang, S-Tronic - B&O, Tech Pack etc... Company Car 1995 Audi A8 4.2 V8 quattro Sport - Bose, Solar, Blinds
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#3
3rd February 2011, 07:27 AM
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I assume it's a right-hand drive car... The work is a bit more involved as there is a lump where the starter motor recesses and this may foul the clutch pedal. I'd be surprised if it wasn't a good bit more to do that getting a recon (or new) gearbox fitted.
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2010 Jag XF 3.0D Portfolio S I know.. I know.. 
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#4
3rd February 2011, 09:50 AM
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Ah yes, pics!
 She is indeed right hand drive, so that would be a factor! This is an older pic, the wheels are standard colour, at the moment they are anthracite/black (got a second set of alloys this colour), I can't really make up my mind which I actually prefer.... She's a 1999, which is quite late for a pre-facelift, and is fairly loaded with goodies! I saw Tozo's posts, mostly on QuattroWorld (do you really have to click into every single post or am I doing something stupid??), but his conversions seem to concern later engines, and he's using an S4 gearbox, as he may not be able to get the normal gearbox in the USA, I don't know all the ins and outs of it. I was thinking of dropping him an email but said I'd post on here first in case anyone has some info? What kind of price to 5 speed S8 auto boxes run at refurbed? I'd be hesitant to buy a second hand box that already has 100k+ considering the issues they seem to have, this was the main reason I was thinking about the manual....
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#5
3rd February 2011, 11:14 AM
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Welcome to the forum. The manual conversion of a RHD is a bit of a holy grail on here. It's something on my 'to do before i die list'. My research shows that a manual box from Europe with peddle set modifed from another VAG vechile is the way to go. Propshaft also required.
Otherwise its a full fabricated afair with an S2 or S6 manual and custom propshaft and pedal set. If you do it please keep us updated; and of course you must come to one of the A8oc events so we can see it!
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Conan (the Librarian) Watch it if you dare Currently, 2000 S8, Merlin Purple, Leather Pack 1, Winter Pack 1, SPAX adjustable suspension, AP Racing 6 pot front caliper, 385mm fully floating disks, EBC Yellow Stuff Pads, Black Diamond grooved rear disks and predetor pads, D2 Doctors Brake Block. 1997 4.2 A8SQ - the Projekt. 12 years and ongoing! 1997 4.2 A8SQ - Ming Blue. Restoration sat waiting; saved from the Scrapyard 2003 C5 Allroad 4.2Q - Cobolt Blue. Towing car. Laid up awaiting manual conversion. 2005 C5 Allroad 2.5TDi FE - Grey - Workhorse. 2015 Q3QS SLine - Daytona Grey. Lots of extras! Long Haired Admirals cutter. Previously 2003 C5 A6 1.9TDI FWD - Loaner from D2 Doctor Lifex 1997 S8 - Ming Blue. Loaned out and written off. I loved that car. My first engine swap after cambelt failure. 1996 4.2 A8SQ - Ming Blue. 178k on a cambelt! Trader's 8. Delivered to A8Parts at Lifex. 2003 2.8 A8SQ - powder blueish. Fill in for a while. Sold on. 1998 1.8T A4 Avant FWD. Ming Blue (there's a theme here), PEX for the 97 S8. And a list of non VAG going back 40 years before I saw the light.
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#6
7th February 2011, 02:20 PM
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I thought RHD A8 D2s have too tight footwell for 3rd pedal. LHD cars have more space in the footwell because there's no electric box from right.
On top of that, if you have quattro then your new gearbox should "match" your final drive. If they "don't match", then front wheels and rear wheels will rotate at different speeds. I would shell out 600 - 1300 pounds for gearbox rebuild. Gearboxes are repairable and will work like new if repaired properly-- I see no problem with that. My own opinion...
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I'd rather drive on left Last edited by notorious; 7th February 2011 at 08:53 PM.
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#7
9th February 2011, 10:48 AM
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Just got the fault sheet from the garage, they asked if I'd know anyone who might
know what all this points to....  Things do not look good for me unfortunately, due to circumstances beyond my control I don't have any money to spend on the car (or anything, for that matter!), so I'm just gonna have to park it for a while if it is the gearbox that needs to be rebuilt. So now I will have 2 cars parked up awaiting funds, the S8 was my daily driver so it puts me in a bit of a bind. With all the **** that's happened in the last year I must be due a lotto win or something! To fufill my curious streak however, does anyone know if the 01E DGV 6 speed that was used in the D2 S8 was used in any other cars?
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#8
9th February 2011, 01:17 PM
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Here are the ross tech wiki outputs for those codes -
17118/P0734/001844 - Gear 4: Incorrect Ratio Possible Symptoms Clutch Slipping Reduced Power Output Possible Causes Gear related Clutch slipping/faulty Gear related Solenoid Valve dirty/faulty Overloaded Clutch due to continuous high Torque or Tuning Wiring and/or Connections faulty Sensor Gear Position Indicator faulty Mechanical Failure Possible Solutions Check Engine Values for Plausibility, especially Torque related ones. Check Wiring and Connections Check Sensor Gear Position Indicator Check Gear Solenoides Special Notes The gear monitoring of the transmission control module checks the gear ratio by comparing transmission input and output speed in regard of the currently selected gear. This fault code is being set when recognizing an implausible transmission ratio. 17114/P0730/001840 - Gear Ratio Monitoring: Incorrect Gear Ratio Possible Symptoms Malfunction Indicator Light (MIL) ON Possible Causes Transmission Fluid contaminated Transmission faulty (Mechanical Problem) Possible Solutions Check Transmission Fluid (Color and Contamination) Replace Transmission Fluid when necessary Check Transmission Mechanics Special Notes Transmission Damage may be caused by Engine Problems, make sure there are no other/relevant Fault Codes stored in Engine Control Module. When found in 6-Speed Automatic Transmission (01J/Multitronic): Instructions on how to check the Transmission Fluid as well as Details on a special Test Kit can be found in TPI 2016661. TPI 2006088 may also be relevant. A conversion from 6 to 7 Clutch Plates may be possible. See TPI 2004856 for Details. 17087/P0703/001795 - Brake Switch (F): Electrical Malfunction Possible Symptoms Malfunction Indicator Light (MIL) ON Possible Causes Wiring and/or Connector(s) from/to Brake Switch (F) faulty Brake Switch (F) faulty Possible Solutions Check Wiring and/or Connector(s) from/to Brake Switch (F) Check/Replace Brake Switch (F) Special Notes When found in Vehicles with Drive-by-Cable (DBC) the Brake Switch (F) is connected to the Transmission Control Module. On older Models this Code is stored automatically after Terminal 15/Ignition is switched ON. If the Brake Switch (F) is OK you can avoid this Fault Code by pressing the Brake Pedal after switching on the Ignition and prior to checking Fault Codes. The Code should automatically be cleared then. When found in Vehicles with Drive-by-Wire (DBW) the Brake Switch (F) is connected to the Engine Control Module In this case you should check the Engine Control Module for Fault Codes as well and the Data Bus Wiring between Engine and Transmission Control Module. 65535 - Internal Control Module Memory Error Possible Causes Control Module housing leaky > Control Module wet Wiring from/to Control Module faulty Control Module faulty Possible Solutions Check/Clean Wiring from/to Control Module Replace Control Module Special Notes This fault is NOT to be ignored when found in a major and/or critical system (Airbag, ABS etc.). When stored in other unimportant systems (Radio etc.) the general suggestion is to ignore it unless you notice functional limitations. Within the warranty period dealers are usually required to replace such control modules, but there have been a couple of cases with similar codes where these are getting ignored due to flaws in the control module software. If in doubt please refer to technical bulletins and similar documents provided by the vehicle manufacturer. Audi Airbag 6 & 7 Problem: A fault of the acceleration sensor may result in the above fault. Solution: Replace Airbag control module and both acceleration sensors. Audi Airbag 8 Problem: Due to under voltage the control module does not complete it's self test successfully. Solution: Replace Airbag control module and install a under voltage protection relay for it. Certain older TDI ECUs which have a vacuum line going to them Problem: Vacuum line broken, either before ECU or inside ECU. Solution: Inspect and repair vacuum lines to ECU and inside ECU. 17114/P0730/001840 - Gear Ratio Monitoring: Incorrect Gear Ratio Possible Symptoms Malfunction Indicator Light (MIL) ON Possible Causes Transmission Fluid contaminated Transmission faulty (Mechanical Problem) Possible Solutions Check Transmission Fluid (Color and Contamination) Replace Transmission Fluid when necessary Check Transmission Mechanics Special Notes Transmission Damage may be caused by Engine Problems, make sure there are no other/relevant Fault Codes stored in Engine Control Module. When found in 6-Speed Automatic Transmission (01J/Multitronic): Instructions on how to check the Transmission Fluid as well as Details on a special Test Kit can be found in TPI 2016661. TPI 2006088 may also be relevant. A conversion from 6 to 7 Clutch Plates may be possible. See TPI 2004856 for Details. I have to say it doesn't look good - 4th gear was what went on my recently failed box If it is that then your only hope is for a rebuild or a service exchange box, or talk to A8 parts to see if they have any reasonable ones there. Good luck with things . . . .
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Confidence is the feeling you have before you know better . . . .  Audi A8 D2 3.7 Quattro Sport 1999 FL - Melange 2nd Place Winner - A8-Freunde Annual German Meet 2012 at Edersee 20" x 9" Bentley GTC Wheels with 385mm W12 Front Discs & Bentley Caliper Covers, Front Lowered on Coilovers, Xenons, Combined DRLs and LED Foglights to modified OEM front fog lamp position, Alcantara/Leather, Full Black Alcantara headlining + pillars and blind shelf, Bespoke Flat Bottomed Sports Steering Wheel, Dark Myrtle Wood, Autodim Mirrors, Bose, Blinds, Digital TV, Ski Hatch, Modified rear exhaust section for extra V8 Burble  Audi S8 D2 Final Edition 2002, Avus Silver with Red Leather Interior Tiptronic with Sport mode button, Sony rear entertainment package, Bose sound system, Audi Navigation Plus, 20 inch Final Edition alloys, Full Cat Back Stainless Milltek exhaust, giving a great V8 burble Audi A8L D2 4.2 Petrol with LPG - Ebony Black Audi A8L D4 FL 4.0T Petrol twin turbo - Havana Black Audi A2 1.6 FSi Sport - Dolphin Grey with Votex body kit and Red Leather Interior and some other A8's A8L's and Mercs Last edited by Architex_mA8tey; 9th February 2011 at 01:20 PM.
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#9
9th February 2011, 01:24 PM
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inplain straight forward english, the transmission ecu asked for gear X, but after gear X should have been engaged, the ECU found that tha ratio between the input and output shafts was an inplausible ratio, ie gear X wasn't selected.
The gearbox is seriously dumb, ie there is no real way of figuring out what is wrong without stripping it down, but 130K on an S8 is a good innings. I concur with other peoples thoughts, if cost efficiency is your goal, then get another auto box. A8parts might have one, and they have a very good idea state it is in. Its not uncommon to have cars in to break through accident damage that have recently had a refurb box in....
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For parts enquiries and Forum User Administration please contact customer services directly, not me - enquiry@a8parts.co.uk, www.a8parts.co.uk, or call 01642 783537The Daily Town Car - 2023 Tesla Model Y Performance. Black with Black. Giant ipad screen, huge sunroof, 4 wheel drive, Tow bar, lots of ooomph and made in China, so actually built properly unlike the Californian ones. The Family Wagon - 2018 Tesla Model X. Black, 7 Seats, Towbar, Homelink, Enhanced Auto pilot with Summon and self park, Heated front seats, CCS Charger upgrade, MCU2 Upgrade, Falconwing Doors, Self opening / closing doors, Netflix, Spotify, toys, Air suspension, alcantara roof + lots of other stuff...... The 17 year old Driver Wagon 2015 Skoda Citigo Monte Carlo. Alloys, Power steering, Aircon, Leccy windows, Sat Nav, bluetooth, central locking, cup holders, 59 whole bhp. Million times better than my first car. Well jealous..... The First 20 Audis: 2001 D2 4.2 QS Silver, 1997 D2 S8 Silver, 1999 D2 4.2 Silver, 2002 D2 S8 Dolphin Grey, 2003 C5 RS6 Blue, 1998 D2 S8 Black, 2000 D2 4.2 QS/S8 Ming Blue, 2003 D3 4.2 Ming Blue, 2005 B7 S4 Blue, 2006 D3 3.0 Tdi Black, 1999 D2 4.2 Silver, 2003 D3 4.2 LPG Crystal Blue, 2000 D2 S8 Silver, 2007 3.0 Tdi Q7 Black, 2009 B8 S4 Black, 1998 D2 S8 Agate Grey, 2006 D3 4.2 Tdi Blue, 2006 D3 S8, 2007 Q7 3.0 Tdi, 2006 C6 S6, The Second 20 Audis: 2011 A7 Sline, 2001 A2 1.4 Tdi Black, 2002 A2 1.4 Tdi Silver, 2006 A8 4.2 Tdi Blue, 2007 4.2 Tdi Q7, 2006 S4 Cab Silver, 2010 RS6 Saloon Black  , 2007 TT Roadster, 2010 A8 D4 4.2 Silver, 2006 C6 A6 2.7 Tdi Quattro, 2000 D2 4.2 QS/S8 Ming Blue (again), 2008 Q7 4.2 Black, 2009 C6 RS6 Saloon Daytona Grey, 2001 Fully Loaded A2 Tdi, 2006 Avant S6 Black, 2007 VW Caravelle Exec Black (almost an Audi) 2009 TT Roadster Daytona, 2015 Q7 4.2 tdi lava grey, 2002 GmbH D2 demonstrator, 2006 D3 A8 LWB 4.2 Tdi Black Most Recent Audis: 2001 A2 1.4 Tdi Black, 2007 4.2 FSi Q7 ABT Blue, 2016 S5 Coupe Launch model, 2004 S4 B6 Cabriolet, 2016 Q7 Sline White, 2006 Q7 4.2 FSi Black, 2012 Q7 Sline+ 4.2Tdi White, 2008 Blue Audi S8 Everything Else 1989 Subaru Justy, 1986 Vauxhall Cartlton 2.0 GL, 1985 Vauxhall Carlton 2.2 CDi, 1987 Ford Sierra XR4x4, 1983 Vauxhall Senator, 1985 Vauxhall Senator 3.0i, 1997 Polo Saloon, 1997 Peugeot 306 1.9 TDi, Ford Sierra Sapphire 2000E, 1990 Subaru Justy, 2000 Subaru Impreza, 2000 Subaru Impreza RB5, 1993 Range Rover LSE, 2005 VW Bora, 2003 Skoda Superb, 2003 VW Passat V6 4 Motion, 1996 Peugeot 106, 2000 Range Rover 4.0, 2019 Tesla Model 3 Performance
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#10
10th February 2011, 10:39 PM
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Or some shoddy crooks have mine 1.5k miles old with a warrantied gearbox
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2009 Audi RS 6 Saloon V10 - 420mm Ceramics, Keyless, Soft Close, Adaptive Cruise, Glass Sunroof, Blinds, Twin Pane & UV, Freeview & DAB, High Beam Assist, MTM bits, Audi Exclusive Bits, MRC, Milltek, GYEF1 ASY2's, Bluetooth streaming music to AMI mod - 753 PS/1021 NM 2016 Audi S3 Saloon, Sepang, S-Tronic - B&O, Tech Pack etc... Company Car 1995 Audi A8 4.2 V8 quattro Sport - Bose, Solar, Blinds
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Hybrid Mode
