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2002 A8L Transmisson ZF5HP24A rebuild

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2002 A8L Transmisson ZF5HP24A rebuild

 
Old 12-27-2013, 06:58 PM
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Removal of another circlip and the smaller clutch housing is removable
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Old 12-27-2013, 07:04 PM
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And the culprit is found! The same stupid O-ring has failed in another gearbox.
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Old 12-28-2013, 03:58 PM
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I wonder how often our transmission problems are just this o-ring.

Tozo - it would be great to hear some of your feedback on this.
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Old 12-28-2013, 07:26 PM
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It seems to happen a lot based on how often this comes up online. We're gonna delve deeper obviously to see if there is wear on any of the other clutch packs or hardware, but so far the only problem has been the O-ring and some minor ware here.
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Old 12-28-2013, 07:33 PM
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The bearing there is also missing one roller. Thankfully I found it sitting there in the fluid. Second part I'll need to order
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Old 12-28-2013, 07:35 PM
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Close up
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Old 12-31-2013, 07:50 AM
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Just curious: has anybody researched adding clutches to the clutch packs for more durability? I remember speaking w/ a guy at ZF America and him saying something to that effect. I figured I'd ask just to see if anybody ever did it
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Old 01-06-2014, 05:54 AM
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I can't imagine there being any clearance for additional clutch packs, unless ZF offer thinner discs (weaker?).

Curious to know how the rebuild is proceeding.

Joe
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Old 01-06-2014, 02:22 PM
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Originally Posted by JoePGT5S View Post
I can't imagine there being any clearance for additional clutch packs, unless ZF offer thinner discs (weaker?).

Curious to know how the rebuild is proceeding.

Joe
It's that exactly Joe. ZF said the clutch basket is different on the RS6 allowing for more clutch discs. Also some differences in the VB and a different torque converter.

I'm currently waiting on the new gasket kit and bearing from the CTSC, so right now the tranny's just sitting patiently on the bench. I think I've decided not to dig any further into the tranny cuz reverse works fine, and I don't want to replace parts that are working ok. If it gives me trouble in the future, I'll just have to pull it out again. Although I'd prob just pull the trans by itself. And my dad has told me in no uncertain terms that he doesn't want any part of that Cross that bridge when I come to it

ATM I'm working on the motor. It was burning oil pretty bad and knocking so we bought a 4.2 from an '03 last week and spent most of the weekend swapping parts to the new one but are finding it doesn't seem to be an "A" grade as advertised (sigh). Oh well, at least forward progress is being made, albeit seemingly kinda slow.

Can't wait to drive it OOOOh
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Old 01-21-2014, 02:40 PM
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Sorry for all the time in between posts the last few weeks have been crazy. Anyway...
Where was I?

The kit arrived from the CTSC; this plus the bearing was $270 including shipping.
All OEM, made in Germany
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