Passat 2.5 TDI: 5-Speed Automatic Transmission

Hello,

I had a customer on Saturday with a 2002 Passat, a 150 horsepower 2.5 TDI engine, and a 5-speed automatic transmission.
In manual mode and with the accelerator pedal fully depressed without using the kickdown function (i.e., at maximum torque), the transmission emitted squealing noises in the range of 1900-2200 rpm. The forward thrust noticeably lagged behind the engine speed.

I suppose this isn't normal? How can this happen after so few kilometers? The car had just about 88,000 kilometers on it.

Best regards, Rainer.

Sounds like it might be the converter. Perhaps there's an issue with the oil level?

Hi,

I'm not sure, but according to the service record, the automatic transmission fluid (ATF) was changed at approximately 60,000 km. However, I stopped working on it due to lack of time, and I'm not really familiar with automatic transmissions.
"Anyway, nothing was leaking oil underneath the car. A repair manual for that part would be really helpful."

Best regards, Rainer.

Hi,

Quote:

According to the service booklet, the ATF was changed at approximately 60,000 km.

VW refers to a "lifetime fill," meaning the automatic transmission fluid (ATF) does not need to be changed. The reason for this is that when the ATF is changed, it often results in too little fluid being added, which can then lead to problems.
I need to search to see if I can still find my old notes about this... If I remember correctly, the ATF (Automatic Transmission Fluid) level needs to be checked within a narrow temperature range while the engine is running (which is almost always the case). If this isn't done correctly, a seemingly too-high level might be measured. And then, when the level is "corrected" based on that incorrect reading, problems start.

Yes, something like that would be great...

Regards,
Sure, here is the translation of the text from German to English:

"Micha"

Yes, VW talks about a "lifetime fill," but if the transmission fails due to oil changes not being performed, the "lifetime" has expired .

It just needs to be interpreted correctly...

Here's a link to the "bible" for TT5 (ZF 5HP19) drivers:
http://www.passat3b.de/phpBB2/viewtopic.php?f=18&t=11295




Sven.

hello,
I also have squeaking noises in my A4 with the Tiptronic transmission.
and specifically at approximately 1500 RPM.
What did you find out back then?

Quote:

Due to a lack of time, I had to stop.

Hello,

My suggestion: First, change the transmission fluid! It doesn't cost much and often fixes most of the issues with the TT5.

Get:
6l ATF (the 'new' Dexron 6 is now recommended by ZF).
MANN Filter Kit.

- Drain the old ATF (Automatic Transmission Fluid).
- Remove the oil pan from the transmission.

Now you can see if there's a major mechanical problem. The ATF shouldn't smell burnt, and there shouldn't be large amounts of metal shavings in the pan or on the magnets in the pan. That grayish 'sludge' is normal, but copper- or brass-colored shavings are a bad sign. Now you know, and you can look for a transmission specialist to discuss a rebuild or replacement transmission.

If that's all okay with you, I'll verschandeln the oil pan, remove the old gasket, take out the old filter, and verschandeln the slide valve.

- insert a new filter.
- Place the gasket on the oil pan, first applying a thin layer of ATF (Automatic Transmission Fluid). Secure the gasket with the pan's screws.
- Reinstall the oil pan, tightening the screws evenly in a circular pattern (until the pan makes contact, hand-tight, then with 10 Nm of torque).
- ATF einfüllen bis es überläuft, die Einfüllöffnung (große Schraube) hat so ne Art Syphon, da kann man wohl auch mit dem Ausziehschlauch der Ölflasche füllen, ich hab ne elektr. Ölpumpe taken
- Start the engine, shift through all gears (P, R, N, D) for approximately 10 seconds each, then turn off the engine.
- Fill the ATF until it overflows.
- Start the engine, shift through all the gears again, put it in Park (P), and leave the engine running.
- Fill the ATF until it overflows, then turn off the engine.
- If you're feeling up to it, you can (or should) check the rear axle oil (fill it until it overflows with GL5 oil).

There are now approximately 5.7 liters of new ATF in the transmission, and a little more probably wouldn't hurt. The important thing is that the temperature doesn't rise above about 35°C. However, if the transmission is cold beforehand (like if your car has been sitting outside and you drive about 1.5 km to the lift), you won't have any problems with that. Now, take it out on the road and hopefully enjoy a 'new' transmission.

I had various problems with my previous car because it wasn't getting enough oil (only about 4 liters came out!).
- Failing transfer case, including a fault in the control unit (no power transmission to the transfer case, or something similar; I initially thought the solenoid valve was the issue).
- Inconsistent shifting (engine speed fluctuations during gear changes, 'mushy' shifting).
- occasional running noises.
Since the change, everything is okay again.

Good luck.
winschrott

Good instructions.
My workshop, due to a lack of knowledge/desperation, filled the oil into the oil cooler line.

What else changes/disappears; the "thump" or "jolt" when slowing down/stopping, just before coming to a complete stop.
Castrol Tranzmax Z (which used to cost 9 euros per liter) has worked quite well so far.
The TT5 seems to really appreciate oil changes.

The servo motor for reverse gear may occasionally fail gradually; it's possible to test this, for example, on a hill, by using the handbrake to see if the reverse gear engages properly as the servo's power diminishes.

Yes, it seems that many people, including authorized workshops that should theoretically only need to consult their manuals, are quickly overwhelmed by the TT5.
The TT5 is supposedly designed to be a lifetime fill. BMW also used this automatic transmission in some model lines, and there's reportedly a 60,000 km interval for changing the ATF (Automatic Transmission Fluid). ZF doesn't like the idea of a lifetime fill either, but they have approved the use of Dexron VI for the transmission because it supposedly better meets the desired long-term performance characteristics. ZF is likely now filling the transmission with this oil from the factory.
For my part, I will from now on diligently change the oil every 60,000 km. It's not really that much effort, and the cost, with just under €70 for the filter kit and oil, is very reasonable. I will just not let a workshop handle the automatic transmission anymore .
- not enough ATF (Automatic Transmission Fluid) inside.
- The oil drain plug was tightened so much that it could no longer be removed without being damaged.
- The oil filler cap had to be opened with a lever that was almost 1 meter long.
- 5 of the oil pan screws (Torx) were actually 'Torx-shaped screws' rather than true Torx screws.
- Glued in place with sealant - completely unnecessary and a real pain to get off.