Looking for a solution to adapt the transmission control

I have a specific renovation problem.
This concerns the transmission control for a Tiptronic automatic transmission with the identification code "FAD" (ZF's 5HP19) from an Audi A6 manufactured in 2000.
Here's what I built:
I installed a TDI V6 engine (AKE, from an Audi A4 Quattro) with a Tiptronic transmission into my T3 van.
During the Tiptronic (direction change) conversion, I took the opportunity to choose a gear ratio that was approximately 12% shorter. My priority wasn't achieving a theoretical top speed of 240 km/h, but rather improved acceleration and responsiveness.
Subsequently, the transmission control system immediately switched to emergency mode.
I initially "worked around" this problem by building a gear ratio output speed converter. This device converts the output speed pulses in a ratio of 1:1.172.
So far, the whole thing works. However, it's not 100% perfect because it's a "clock multiplier" rather than a clock divider. This problem isn't trivial and requires very high processing power from the processor being used (and therefore doesn't run completely flawlessly).
Surely there must be a way to change the gear ratio in the transmission control?
According to my research, it is impossible without the corresponding "DAMOS file."
Who can help me with this problem?
If you are interested in the renovation documentation, I can provide it to you.
Greetings from Berlin.
Norbert.

Hello Norbert,

From my gut feeling, it seems that

Quote:

fixing this problem

is more likely to be successful. This issue is not as trivial as it appears and requires very high processing power from the processor being used (and therefore doesn't run completely error-free).
Of course, there's always the exception of someone who has already dealt with Tiptronic in this regard...

What signals does your frequency converter use, and which microcontroller are you using?

Best regards, Rainer.

...Of course, this doesn't apply if someone has already dealt with Tiptronic before...

Hello Rainer,

I'm looking for exactly that.
I already asked Audi -- they said the 5HP19 is too old, and no one there has any experience with it anymore.
I even contacted a chip tuner (who has the DAMOS file for the 5HP19 transmission control units), but their willingness to help was close to zero; or they wanted to see a four-digit amount for research work.
I have no connection to ZF.
Let's see, maybe there's someone knowledgeable in this forum or someone who knows someone .
Anyway, I don't want to touch the DC-DC converter anymore. I'm just glad it's still running (and has been for over 10 years).
I also started by building an analog switching regulator.
Convert impulse values to Ohmic values -> Modify the Ohmic value by a factor of 1:1.172 -> Convert the Ohmic value back to impulse values. This works, but only at a constant temperature. Even the highest quality resistors change their value, which ultimately limits its effectiveness.
I had also considered having the original translation created, but the gear manufacturer (Bufe company) has since disposed of all drawings and sample gears. This means that conducting gear research from scratch would be too expensive.
I wish everyone a happy holiday season and a good start to the year 2016.
Greetings from Berlin.
Norbert.

Hello,

How did you build the converter?
At what deviation does a malfunction occur?

Perhaps we can optimize the programming of the translator. It shouldn't require that much processing time; after all, we're not talking about something running at 50,000 RPM .

Hello DaBibu, first of all, thank you for the reply.
I'm currently traveling in East Africa and will get in touch when I return.
Greetings from Dar es Salaam.
nobu

Where is the output speed of the gearbox measured? Before or after the differential?
If you're planning to install a differential before the existing one, you could remove the reduction gear and replace your current differential with one from an Audi Allroad. The Allroad differential is significantly shorter than the one found in the A6.

Hello Tagessuppe, the output shaft speed of the transmission is measured before the differential. Therefore, changing the differential will not improve anything. Since the transmission is installed in a T3 vehicle, I had to build a reverse rotation mechanism. The original gear ratio was 48 to 49 teeth. Now it's 46 to 54. Currently, I have built two solutions:
- analog -> Wandlung Drehzahl in Widerstand. Dann Änderung des Widerstands analog zur Übersetzungänderung. Anschließend Wandlung in Drehzahltakt. Funktioniert solange keine Temperaturschwankungen. SonPlease provide the text you would like me to translate from German to English. I need the text to be able to give you a translation.
- digital: A device that converts the clock cycles to a specific ratio. It works quite well (but not perfectly).
That's why my question is whether anyone can change the gear ratio that is stored in the transmission control unit. This solution is much more elegant. According to my information, however, a suitable DAMOS file is required for this.
Best regards from Kigali (Rwanda).
nobu

Hi there,

Actually, this should work perfectly well with an f/V and a U/f converter. It's also quite stable over a fairly wide temperature range. The first converter generates a proportional voltage from the speed, which you then reduce using a (adjustable) voltage divider so that the second converter (U/f) outputs the corresponding frequency.
It seems highly unlikely to successfully hack the transmission control software unless you happen to catch a developer who still has access to the source code.

Best regards from Berlin,
Okay, please provide the German text you would like me to translate into English. I will only provide the translation.

Quote:

Darum meine Frage, ob jemand das, im Getriebesteuergerät hinterlegte, Übersetzungsverhältnis ändern kann. Diese Lösung ist wesentlich eleganter. Nach meinen Informationen ist dafür aber das passende DAMOS-File notwendig.

The Damos file is a component of it, but there's much more involved.
Ask in the chip tuning forum; perhaps someone there has already tuned similar "exotic" modifications. Some people there are already experimenting with transmission control units.

"Hi, have you already contacted ZF with a technical inquiry? Perhaps someone there can help you. However, for ZF, this might be legally complicated (modified software would need to be approved), but they might at least be able to suggest possible solutions."

http://www.zf.com/corporate/de_de/meta/contact/technical_inquiries_zf/technical-inquiries.jsp

VG

Hi there,

I know this thread is old, but how did you solve the issue with the transmission?

I'm experiencing a similar issue, and perhaps you could help me.

Regards,

Chris.