Sleeper8

Tuesday night I pulled an all-nighter and finished reassembling the A-car. It appears that the transmission rebuild is a success. I installed a complete overhaul kit which consisted of all the seals and o-rings in the transmission, but not including the friction plates and steels. I also made the measurements and adjustments to each clutch pack as prescribed by the manual. As was the case with the only other trans that I have ever rebuilt (a 4hp22 from my BMW), there was very, very little wear in evidence on any of the hard parts (car has 160k). F clutch was definitely the issue. The entire trans can be disassembled with very few tools. Outside of a T-27 and T-40 torx drivers, only rudimentary tools are needed. Some improvising is required where special fixtures are called for, but I had no problems making do with what I have. For reference, here is what I spent on the trans rebuild:

O/H kit (mostly rubber bits and seals) $252
5HP24A Manual $75
Rebuilt torque converter $325
New snap rings $16
New F-piston $30
Intermediate shaft bearing (destroyed in removal) $32
Audi ATF G052162A2 (you can get this cheaper ) $230

Hours to rebuild: About 25-28 from the time I split it from the engine to the time I bolted it back on. I could probably do it again in about 15-20, but I am very meticulous about cleaning and reassembling things and torquing correctly, etc.

I purchased everything from Eriksson Industries. They had everything I needed in stock and shipped same day. http://www.erikssonindustries.com/audi.htm

Here's the transmission in its most disassembled state, the F-clutch is disassembled on the little workbench:
<img src="http://i48.photobucket.com/albums/f202/G1968Y/2000_A8_Engine/DSC_0939.jpg">

Other items I fixed while I had it apart:
Oil cooler - new plastic pipe and seals
Alternator - new brushes / VR
Starter - disassembled, cleaned and lubed, brushes were at about 60-70%
Replaced all 4 O2 sensors with Bosch OEM's
Variable intake runner system
Power steering flush

I probably spent more time cleaning parts than anything else in this job. When I first re-started the car, I had a flashing CE light. So I pulled the codes and consulted the Bentley, within 5 minutes I was able to find that I had not snapped the MAF sensor connector in tightly and the car was purring with no CEL illumination. It was about 4 A.M. and -14° outside, but I could not wait, so I took it for a test drive but stayed close to home. It was quickly revealed that I had pulled one big boner in re-assembly. The ABS light came on and I realized that I had not re-tightened the axle collar bolts (the bolt on the outer end) which never actually needed to be loosened anyway, so I will probably be doing front wheel bearings soon. All in all, I am very satisfied - the car runs great and the shifts are smooth and positive, including the TC lockup. I did a complete front end job with all new OEM control arms and rebuilt axles less than 20k ago, so the car runs and drives like it has 16k on it instead of 160k, which is great because it is still a beautiful car and I hope to run it for another 100k at least. It will get a full alignment at the dealer tomorrow A.M. and then I will turn it back over to my DW who has been a real trooper driving my Chevy HD Crew Cab pickup for the last six weeks with almost nary a whine. Here it is outside my office today:
<img src="http://i48.photobucket.com/albums/f202/G1968Y/2000_A8_Engine/DSC00321-m.jpg">

Jkay

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DaveInSaltLake

LF corner of the red Audi? What brand is it? This is the one I recently purchased after spending WAY too much time researching:
<img src="http://i47.photobucket.com/albums/f174/DavesData2/2001%20A4%2018t/transmission/ClutchC/DSCN7390.jpg" border="0" alt="12">

I'm surprised to see so much difference between the 5HP19 I'm working on and the 5HP24. The area where the valve body bolts up is radically different:

<img src="http://i47.photobucket.com/albums/f174/DavesData2/2001%20A4%2018t/transmission/DSCN7370.jpg" border="0" alt="Photobucket">

The problem in my A4 trans was apparently a burnt C Clutch, but I don't have the car back together yet and haven't tested it.
<img src="http://i47.photobucket.com/albums/f174/DavesData2/2001%20A4%2018t/transmission/ClutchC/DSCN7398.jpg" border="0" alt="4">

This was my first forray into an auto trans that I actually intended to put back together. I can't express enough gratitude to our resident tranny expert who took the time to coach me through several key steps.

pkrasusky

...(or more likely worse!?)... I too once neglected to torque the humungous LF axle bolt on my UrS6.

sadly

the bearing f'd the pooch about 20-30k later.

Great job tho regardless.

Sleeper8

I actually used some cut-off iron pipe sections and c-clamps to compress the springs. It was crude but worked well.

DaveInSaltLake

different kinds of PVC couplings under a 2" diameter pipe lever wedged under a jack stand and quickly gave up. The right tool made a WORLD of difference because of all the adjustments and pivots.

JMohn

Very Impressive!

OOOOya

...and the wifes A6 was apparently eager to get on it. The alternator died last Thursday night.

tozoM8

It is nearly impossible to remove it undamaged without the puller.

mAgnum8

Awesome work, very impressive. Now you have a new car.