Transmission out...and everything else that followed

[anditsoundslikebells]

I bought my '02 6 early last year and it has taken until now to get it to where it needed to be. I wouldn't have been able to do it without the knowledge and help in these fabled forums so thanks to everyone that helped along the way.
I bought it nice and shiny, about 145,000km, my perfect colour, summer pack, mobile phone option (with an Audi phone), aluminium trim, everything I was looking for. Unfortunately, it was the first car I looked at so there has been a steep learning curve. These weren't in the sales description, but it had: OC.T full exhaust/200 cell cat/decat downpipes, KW-V3, Stratophere Hyperboost diverter-valve.

I took it to JD Engineering to be dyno'd to see what I'd bought, that's where the story starts, TC slipping, Trans rebuild, a familiar story. As I learned that meant engine out then it was a good time to see to all the bits I might want to do on the car.
Finding someone to rebuild and strengthen the transmission was interesting, in the end, I went with Teo from Teo Motorsport in Poland. Nice guy, ZF specialist, good price, Ricky Elders also recommended him, explained everything, I'm happy with it.

I explored the following:
Sportmile: not helpful at all, just wanted me to send him the transmission with no discussion. didn't get to the price
RS Engineering: helpful, EUR9-10k upgrade rebuild (no install) (EUR6-7k billet parts only). Eur4/5k for a normal rebuild (no install). Didn't go into specs of the normal rebuild as I couldn't afford it.
Getriebe Doc: Didn't speak to, build really strong auto boxes for high powered drag racers. I was told by someone they rebuild transmissions for RS Engineering.
ZF: Reconditioned only
Teo: Torque Converter Spec: Cut/weld. Change valve body seating. On the new ZF increase torque a little bit on spring, to get more resistance. Reduce distance at the face of TC for oil, to reduce slip. (TC, could produce new central veins) not enough cars to produce bespoke, 5 a year.
Valve body: Change spring. Produced by Teo, higher pressure.
Input shaft 1.85 OE new model, up from 1.65.
ZF overall kit
More friction plates:
Original OE friction plates made thinner steel plates. Exody or Borg Warner for ZF friction plates.
4th gear has 2 more plates (8 instead of 6)
2/3 6 instead of 5
A clutch is standard. Stong enough
B 4&5 2 more FP
C only reverse
D 3&5 2 more FP
E 2 1 more FP
Brake F
Transmission good for service at 60k. ZF Liveguard 6 transmission oil 6-speed.
Strongest they have made is 650bhp 800Nm (can be worn out after 40K(km)
For this build recommends 580bhp 650/700Nm
My original quote was EUR2k rebuild only (2 days), EUR3k Install/rebuild (5days). In the end, I had some other work done so I spent a bit more. I drove the car there and left it with Teo.

When it was apart it transpired that the TC was not going to be up to the task for an uprated engine. We sourced a new one off the shelf from Audi Germany, interestingly when I spoke with ZF directly, they have no stock left and could only offer me a reconditioned TC.

While the engine was out I sent the turbos to TTH who rebuilt them to 620PS and Teo installed. I paid TTH EUR1600 (seems to have gone up now?).
https://www.ebay.de/itm/Upgrade-Turbola ... SwajVUSJlF
TTH spec: The OEM Borg Warner 5304988 0028 & 0029 Turbochargers come with the following changes optimized:
-Extended Tip compressor wheels with the latest Compressor geometry
-Gap optimization by CNC turned Compressor housing
-Turbine bevel for less exhaust gas pressure
-Reinforced bearings
-Fine balancing up to 0.05g

Teo also got a motorsport friend of his to service the engine while it was out: (with 034 Motorsport uprated engine & transmission mounts +transistor bypass)
Camshafts seals, Crankshaft front and back seals, Camshafts cover gaskets, Camshafts tensioners gaskets, Tensioners slides, Camshafts plugs, Timing camshafts chains, Back cover gasket, Engine ventilation gasket, Thermostat, Sparks set, Detonation sensors 3 pcs, Intake manifold gaskets, Exhaust manifold gaskets, Turbo bolts set, Water manifold o-rings.

I then drove the car back from Poland to Rotterdam. Martin from MP Carworks then took the car and we got to the next task, suspension:
OZ Superturismo LM 9.5 x 19 ET40 + MICHELIN P-SP 4 S 255/35ZR19
034 Motorsport: density line adjustable upper control arm kit & lower control arm kit, uprated tie-rods, Spherical rear sway bar links + front uprated links
H&R ARB 33524-1
SKF Top Strut mount

We lowered it and made the KW firm, and I'm now very happy with it, it's planted, doesn't rub, even with seats down/loaded up. It is a bit bumpy but I guess that's the compromise. I can just fit my finger between the inner wing and tire.
We fitted KW Rebound Damping adjustment on the rear so I can play with that from in the car:

Then to the other parts before being set up......Wagner intercoolers, 034 Motorsport billet check valve, DW400 in-tank pump, BMC air-filters, braided brake hoses.

I then sent the TCU to the States so 034 Motorsport could flash on their Trans Optimised Chip:
https://store.034motorsport.com/c5-audi ... grade.html

Final stop was JD Engineering so Martijn could map it for me. We ended up here 580bhp / 790Nm. At this level the shift is smooth in every situation. It's also what Teo recommended so happy with that.

This Christmas I replaced the warn aircon control unit, parking & ESP buttons, and broken rearview mirror. Also fitted two extinguishers, Garmin Dashcam, and the better design of front/rear wipers.

Next on the list are brakes, 2x AEM wideband failsafe gauges, and a 'platform-roof-rack solution' for the across Europe missions.

Here it is sat on the South Coast looking out to the Isle of Wight:

Now I've written it all down it doesn't seem that much of a headache....... but at times it was!
Thanks again to everyone that educated me along the way!

[Mark-RS]

Great work ! And really nice write up, I enjoyed reading that

What was your overall figure for the work if you don't mind me asking ?

[IchBautAuto]

Great writeup. Good to see what people might offer on the auto trans front.

[Lander91]

Sheesh, epic!

[Gregstv]

Great stuff.
If I drop my KW,s that low there is stuff all travel left in the shock. Makes it ride quite hard. Ended up lifting mine to get some shock travel and a better ride.

[Foxmeister]

Thats dedication

Nice, and should be less hassle for quite some time now, looks great

[anditsoundslikebells]

Once I started I knew I'd be keeping the car long enough that I should do everything right.
My one regret is not having a garage I can work in so I could have a go at doing more of the work myself. I guess that is for the other car sometime in the future.
I certainly spent more than I initially wanted to and with the current market I won't get it back. I'm OK with that, if/when I keep it for 10 years then it averages out and I wouldn't like to have spent a still significant outlay on the car and it not be right/as I wanted.
One killer is the Dutch car market. All cars are crazy prices compared to the UK, kills me every time I cruise autoscout looking at a future project (not that I can afford it).
As an example, I paid EUR22k for mine, it was valued at EUR26k by a specialist for the insurance. Compared to the UK that seems crazy money.
The Dutch government has made it very expensive to register foreign cars so it is it's own little expensive-secondhand-car-market.
The car being more expensive some how makes me feel better about the resto/modification outlay as it was a smaller percentage of the cars value.