Gearbox life survey

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Shoppinit
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Post by Shoppinit » Wed Feb 02, 2011 11:25 am

Thanks for tidying that up.

Audi stopped being embarassed by this kind of thing ages ago. I wonder what it would take to embarass them these days.

How did you diagnose your TC in the end?
Daytona RS6 C5 Avant. Viper'd, Billies, Waggers, MTM box brain, C6 stoppers, xcarlink, R8 coolant cap (woohoo)
///M3 E46 | XC90 (V8, natch) | Passat GTE | RR Classic V8 flapper
"The major difference between a thing that might go wrong and a thing that cannot possibly go wrong is that when a thing that cannot possibly go wrong goes wrong it usually turns out to be impossible to get at and repair."

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JCviggen
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Post by JCviggen » Wed Feb 02, 2011 11:45 am

Shoppinit wrote: How did you diagnose your TC in the end?
VCDS logging lockup status, converter slip and input torque. It slips from ~250 Nm onwards which is not even half of the engine's max. tq.

Image

Drained fluid (well, only got a bit more than half out of it) was pitch black. Shifts marginally smoother with fresh fluid added but no change with the clutch slipping. It's just worn away methinks.

Box is going to a ZF approved shop for a rebuild. Not going to risk just doing the TC...car is only going to be in europe once and I'm not driving back 1800 miles just to find out that it's buggered.

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Shoppinit
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Post by Shoppinit » Wed Feb 02, 2011 11:54 am

I completely agree with getting the box done at the same time. I have heard of so many stories where the box fails a month after the TC is changed. The black fluid is the giveaway :(

I just looked at my logs and whenever my TC is closed the slip speed (or stall speed as my VCDS calls it) is 0 which I take to mean the TC is ok for the time being.

I wonder if it is worth considering changing the TC as preventative maintenance? Add it to the list of things to do while the engine is out of the car.

Or do the brake bands in the box wear at the same time as the clutch in the TC? Who knows :(
Daytona RS6 C5 Avant. Viper'd, Billies, Waggers, MTM box brain, C6 stoppers, xcarlink, R8 coolant cap (woohoo)
///M3 E46 | XC90 (V8, natch) | Passat GTE | RR Classic V8 flapper
"The major difference between a thing that might go wrong and a thing that cannot possibly go wrong is that when a thing that cannot possibly go wrong goes wrong it usually turns out to be impossible to get at and repair."

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JCviggen
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Post by JCviggen » Wed Feb 02, 2011 12:06 pm

I think in the vast majority of cases it's the TC that sets of the chain of events leading to malfunction. "normal" clutch wear already leaves boxes with sludge deposits after a good amount of miles. Slipping TC is going to multiply several times the amount of material contaminating the box in a short period of time. And the pressure drop from the leaking seal that causes the TC slip doesnt do good either. If the TC didn't go south so quickly I think most boxes would reach respectable mileage and we might have seen 5 times or so less box failures. But all we can do is guesstimate. So yes I would consider doing the TC as preventative maintenance IF the engine is out. It doesn't cost that much as a part.

Have ordered an MTM TCU chip too...looking forward to a hopefully smoothly functioning box with more pleasant behaviour.
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Shoppinit
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Post by Shoppinit » Wed Feb 02, 2011 12:11 pm

Yes, the MTM TCU is good. Make sure you get the right chip version for your TCU. It seems that the US TCU s different to the EU version and requires a different chip.
Daytona RS6 C5 Avant. Viper'd, Billies, Waggers, MTM box brain, C6 stoppers, xcarlink, R8 coolant cap (woohoo)
///M3 E46 | XC90 (V8, natch) | Passat GTE | RR Classic V8 flapper
"The major difference between a thing that might go wrong and a thing that cannot possibly go wrong is that when a thing that cannot possibly go wrong goes wrong it usually turns out to be impossible to get at and repair."

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Post by JCviggen » Wed Feb 02, 2011 12:12 pm

Ya I mentioned it was a EURO car and they said no problem (hoppen)
B7 RS4 saloon Misano red, comfy seats, JHM tune & JHM full exhaust with cats and resonators - gone.
C5 RS6 Avant Daytona/Cognac - gone.
981 Cayman GTS Gray/Orange.
My youtube

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Re: Gearbox life survey

Post by Shoppinit » Thu Jun 09, 2011 2:23 pm

Bump...
With all the gearbox hari-kari going on, might be time to update this thread...
Daytona RS6 C5 Avant. Viper'd, Billies, Waggers, MTM box brain, C6 stoppers, xcarlink, R8 coolant cap (woohoo)
///M3 E46 | XC90 (V8, natch) | Passat GTE | RR Classic V8 flapper
"The major difference between a thing that might go wrong and a thing that cannot possibly go wrong is that when a thing that cannot possibly go wrong goes wrong it usually turns out to be impossible to get at and repair."

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rossi46
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Re: Gearbox life survey

Post by rossi46 » Thu Jun 09, 2011 8:13 pm

Good idea ; I'd be interested to hear of any updates too.
( Currently trying to decide whether to go down the ' leave well alone ' route, or have the gearbox serviced come MOT/service time )

Cheers

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Re: Gearbox life survey

Post by MalcolmSu » Thu Jun 09, 2011 8:41 pm

Failed/failing
1. Rupert (2004) Standard power, failed at exactly 60k miles
2. paulm (2002) mrc Stage 1 at 40,000 ish. tc failed 42,000 mls (going manual)
3. batty (2004) STD 61k, gearbox replaced at 57k, no fluid change prior to that.
4. paul23 - STD till 30k, gearbox service at 25k, failed TC at 26k. MTM remap at 30k and on 31k now.
5. Mooch - standard when bought at 20ishk but box started to slip around 22-25k, grizz mapped it and it failed fairly soon after, (it was actually hunting only) gearbox replaced by Audi and not done well- lost oil due to ALL sump nuts only finger tight- grizz sorted.. serviced at 40k all fine. TCU mapped and all ok until 80k. now running big torque and box does not like it. 89k. but still going well if handled with care!
6. skyegtb - New box at 25,000 miles was running MTM 535 then, not sure of failure (previous owner). Now 52,000 miles and been MTM 568'd at same time as box replaced. G/Box service at 40,000 miles, all good, no issues so far, smooth as silk.
7. w8pmc - had 2 boxes go during ownership. 1st at about 15K miles & the car was stock (had only owned it about 2 months) Soon after i had the car tuned to Sportec/AmD Stage 2-3 & was putting out over 560BHP & lbsft & the box (mapped during tune) was fine through to 40K miles when it failed again. Sold the car soon after that.
8. p3u - clutch packs and tc went due to loss of pressure in system at ~91k miles. Stock other then Milltek exhaust at the time.
9. Hartge (2004) MTM Stage 1 (ECU & TCU) @16k. First box failed at 35k, second at 49k
10. Golffather (previous RS6 saloon) 2003 - MRC Stage 1+, Milltek. Total failure at 54k miles.
11. GregRS6 2003 Bought it with a so called gearbox warranty at 84K. engine and box out again 86K
12. GardinerG (2003) Stock when gearbox went at 36k miles. West Tuned & touch wood all is fine at 63k. Gearbox Service in 2 weeks (fluid & filter etc)...
13. spurtle (2003) MRC Stage 1+, TC failed @ 50k miles. Will change ATF every 20k from now on.
14.Grizz-new box fitted at 80k , stage 2 car ..
15.Billiemapped new box fitted and remapped at 51k...
16. mrmule: Box #1 failed at 68k. Regular ATF flushes by MRC. Standard ECU.
17. JCviggen (2003) Stock, TC is gone at 65k. Never serviced.
18. Seanypeeps Standard.Full audi service history 2004 salloon.Gearbox fail at 39578K.
19. marv8 had a new gearbox supplied and fitted at 39167 had a "repair" due to gearbox oil leak at 40469 (issue with replacement maybe as seems too few miles???)
Now at 49k and TC failed, swarf in gearbox so rebuild with uprated drum and new clutch packs (plus a few other bits) Car standard AFAIK.
20. MalcolmSu (2004) Standard. Bought at 36k miles just turned 93k miles and gearbox failed cause yet to be determined. Never serviced AFAIK

Never Failed
1. Dave (2003) MRC Stage 1+ at 80K, still going strong at 110K, box serviced at 80K
2. Gorwanvfr Standard power 39,000 mls still going strong (Never touched)
3. el_ringo (2003) STD until 55,000 mi (Oct08) CCode 1, a 'box service at 60,000 (Mar09) now at 75,000mi (Feb10)
4. CliveH (2002) AMD code since mid 06 55k, gearbox service at 60k (Oct06), still going strong at 90k
5. RS6Steve (2003) Standard 63K still okay (Gearbox full service 62k, No debris)
6.Shoppinit 75000 mls with no problems. ATF changed at 70k and will be at every service now. ATF was clear and clean.
7. Steve Cuz (2003) STD 77k, Gearbox ok, (2 gearbox services in 2009)
8. ecain63 - bought at 50k. MTM1 on ECU and TCU @ 51k. Box serviced every 20k since. Still tight as a Nunns chuff and hit 90k mark today.
9. RS6-4dr911 – 48k mi on original, MTM TCU at 35k, fluid changed at 40k, flushed at 46k, clean fluid on both, will flush every 20k hereafter, just now flashed ECU to Eurocharge Stg.1,
10. woodlum (2002) STD 48k, no probs and works fine, never been serviced, undecided as to service or not??
11. RS6_Dave (2003) Std til 27,500, then MRC Stage 1+ , box map with Service, MRC stage 2 @34k, no probs yet and just turned 40k.
12. MoRS6+ RS6plus, STD, 26k, original ATF, smooth as ice.
13. Bazza (2003) Oettinger remap on ECU/TCU @ 29K (2006) now 39k...fingers crossed all OK
14. Coullboy (2004) GregR1's old motor. Gearbox oil + Filter etc 57K(£360 Specialist cars Aberdeen) , seems to be fine. Engine Standard (59K now).
15. 500bhp (2003) Grizzed, CC Stage2 + TCU, Gearbox oil + Filter etc 95K. All fine
16. Knutts (2003), STD, 78k, no probs and never been serviced.
17. Robrs6 (2003) STD, 88K, Box serviced at 50K, still going strong.
18. C5NVS (2003) STD, 58k, owned since 55k and no clear evidence of service (FASH and considering Audi "lifetime" ATF stance, suspect no service), gearbox still drives like new.
19. Fizmo100 (2003) STD, 70k, Just bought, no apparent issues, but currently having a Unit 20 gearbox service just to be on the safe side!
20. jamesthecat (2003)STD 48k no probs but just waiting for atf oil from audi to service it.
21. jd_Hants (2003) Gearbox serviced 80K. MRC Stage 1+ @ 85K, 95K now
22. Condor24 .. May 2003 .. 46,000 miles to date .. I think serviced by Grizz February 2009
23. viffer. Standard, 72K. Gearbox service at 42K (Camberley Audi)
24. aka_dk (2004) STD, 103k, no problems, gearbox serviced at 101k
25. zip929 (2002) STD, 98K, no service and no probs.

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Re: Gearbox life survey

Post by MoRS6+ » Thu Jun 09, 2011 9:51 pm

It's rather a shame the thread has lost its 'ticking bomb' icon, lol. Was rather apt..

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bakustax
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Re: Gearbox life survey

Post by bakustax » Fri Jun 10, 2011 5:51 pm

rossi46 wrote:Good idea ; I'd be interested to hear of any updates too.
( Currently trying to decide whether to go down the ' leave well alone ' route, or have the gearbox serviced come MOT/service time )

Cheers
Rossi.....I was in the "leave well alone" camp....see my "Oh F*ck" post.
I've got the car booked into get an ATF service...so depending on what happens after that could be a good yardstick.
Mine had shown no signs of any problems until a couple of days ago on the drive home from work....when things took a decided turn for the worse....I'm off to Baku for a couple of weeks but will report back on what the ATF service has done for mine.

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Re: Gearbox life survey

Post by stealthyspeeder » Tue Jun 21, 2011 10:17 pm

Failed/failing
1. Rupert (2004) Standard power, failed at exactly 60k miles
2. paulm (2002) mrc Stage 1 at 40,000 ish. tc failed 42,000 mls (going manual)
3. batty (2004) STD 61k, gearbox replaced at 57k, no fluid change prior to that.
4. paul23 - STD till 30k, gearbox service at 25k, failed TC at 26k. MTM remap at 30k and on 31k now.
5. Mooch - standard when bought at 20ishk but box started to slip around 22-25k, grizz mapped it and it failed fairly soon after, (it was actually hunting only) gearbox replaced by Audi and not done well- lost oil due to ALL sump nuts only finger tight- grizz sorted.. serviced at 40k all fine. TCU mapped and all ok until 80k. now running big torque and box does not like it. 89k. but still going well if handled with care!
6. skyegtb - New box at 25,000 miles was running MTM 535 then, not sure of failure (previous owner). Now 52,000 miles and been MTM 568'd at same time as box replaced. G/Box service at 40,000 miles, all good, no issues so far, smooth as silk.
7. w8pmc - had 2 boxes go during ownership. 1st at about 15K miles & the car was stock (had only owned it about 2 months) Soon after i had the car tuned to Sportec/AmD Stage 2-3 & was putting out over 560BHP & lbsft & the box (mapped during tune) was fine through to 40K miles when it failed again. Sold the car soon after that.
8. p3u - clutch packs and tc went due to loss of pressure in system at ~91k miles. Stock other then Milltek Exhaust at the time.
9. Hartge (2004) MTM Stage 1 (ECU & TCU) @16k. First box failed at 35k, second at 49k
10. Golffather (previous RS6 saloon) 2003 - MRC Stage 1+, Milltek. Total failure at 54k miles.
11. GregRS6 2003 Bought it with a so called gearbox warranty at 84K. engine and box out again 86K
12. GardinerG (2003) Stock when gearbox went at 36k miles. West Tuned & touch wood all is fine at 63k. Gearbox Service in 2 weeks (fluid & filter etc)...
13. spurtle (2003) MRC Stage 1+, TC failed @ 50k miles. Will change ATF every 20k from now on.
14.Grizz-new box fitted at 80k , stage 2 car ..
15.Billiemapped new box fitted and remapped at 51k...
16. mrmule: Box #1 failed at 68k. Regular ATF flushes by MRC. Standard ECU.
17. JCviggen (2003) Stock, TC is gone at 65k. Never serviced.
18. Seanypeeps Standard.Full audi service history 2004 salloon.Gearbox fail at 39578K.
19. marv8 had a new gearbox supplied and fitted at 39167 had a "repair" due to gearbox oil leak at 40469 (issue with replacement maybe as seems too few miles???)
Now at 49k and TC failed, swarf in gearbox so rebuild with uprated drum and new clutch packs (plus a few other bits) Car standard AFAIK.
20. MalcolmSu (2004) Standard. Bought at 36k miles just turned 93k miles and gearbox failed cause yet to be determined. Never serviced AFAIK
21.stealthyspeeder (2003) stock - 84k miles - full audi service history (no gearbox service) - got a rebuild, was told that everything in the gearbox had burnt out

Never Failed
1. Dave (2003) MRC Stage 1+ at 80K, still going strong at 110K, box serviced at 80K
2. Gorwanvfr Standard power 39,000 mls still going strong (Never touched)
3. el_ringo (2003) STD until 55,000 mi (Oct08) CCode 1, a 'box service at 60,000 (Mar09) now at 75,000mi (Feb10)
4. CliveH (2002) AMD code since mid 06 55k, gearbox service at 60k (Oct06), still going strong at 90k
5. RS6Steve (2003) Standard 63K still okay (Gearbox full service 62k, No debris)
6.Shoppinit 75000 mls with no problems. ATF changed at 70k and will be at every service now. ATF was clear and clean.
7. Steve Cuz (2003) STD 77k, Gearbox ok, (2 gearbox services in 2009)
8. ecain63 - bought at 50k. MTM1 on ECU and TCU @ 51k. Box serviced every 20k since. Still tight as a Nunns chuff and hit 90k mark today.
9. RS6-4dr911 – 48k mi on original, MTM TCU at 35k, fluid changed at 40k, flushed at 46k, clean fluid on both, will flush every 20k hereafter, just now flashed ECU to Eurocharge Stg.1,
10. woodlum (2002) STD 48k, no probs and works fine, never been serviced, undecided as to service or not??
11. RS6_Dave (2003) Std til 27,500, then MRC Stage 1+ , box map with Service, MRC stage 2 @34k, no probs yet and just turned 40k.
12. MoRS6+ RS6plus, STD, 26k, original ATF, smooth as ice.
13. Bazza (2003) Oettinger remap on ECU/TCU @ 29K (2006) now 39k...fingers crossed all OK
14. Coullboy (2004) GregR1's old motor. Gearbox oil + Filter etc 57K(£360 Specialist cars Aberdeen) , seems to be fine. Engine Standard (59K now).
15. 500bhp (2003) Grizzed, CC Stage2 + TCU, Gearbox oil + Filter etc 95K. All fine
16. Knutts (2003), STD, 78k, no probs and never been serviced.
17. Robrs6 (2003) STD, 88K, Box serviced at 50K, still going strong.
18. C5NVS (2003) STD, 58k, owned since 55k and no clear evidence of service (FASH and considering Audi "lifetime" ATF stance, suspect no service), gearbox still drives like new.
19. Fizmo100 (2003) STD, 70k, Just bought, no apparent issues, but currently having a Unit 20 gearbox service just to be on the safe side!
20. jamesthecat (2003)STD 48k no probs but just waiting for atf oil from audi to service it.
21. jd_Hants (2003) Gearbox serviced 80K. MRC Stage 1+ @ 85K, 95K now
22. Condor24 .. May 2003 .. 46,000 miles to date .. I think serviced by Grizz February 2009
23. viffer. Standard, 72K. Gearbox service at 42K (Camberley Audi)
24. aka_dk (2004) STD, 103k, no problems, gearbox serviced at 101k
25. zip929 (2002) STD, 98K, no service and no probs.

Crazylarry
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Re: Gearbox life survey

Post by Crazylarry » Tue Jul 26, 2011 5:30 pm

How many of you guys have warranties? :wink:

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Re: Gearbox life survey

Post by bam_bam » Tue Jul 26, 2011 11:05 pm

Failed/failing
1. Rupert (2004) Standard power, failed at exactly 60k miles
2. paulm (2002) mrc Stage 1 at 40,000 ish. tc failed 42,000 mls (going manual)
3. batty (2004) STD 61k, gearbox replaced at 57k, no fluid change prior to that.
4. paul23 - STD till 30k, gearbox service at 25k, failed TC at 26k. MTM remap at 30k and on 31k now.
5. Mooch - standard when bought at 20ishk but box started to slip around 22-25k, grizz mapped it and it failed fairly soon after, (it was actually hunting only) gearbox replaced by Audi and not done well- lost oil due to ALL sump nuts only finger tight- grizz sorted.. serviced at 40k all fine. TCU mapped and all ok until 80k. now running big torque and box does not like it. 89k. but still going well if handled with care!
6. skyegtb - New box at 25,000 miles was running MTM 535 then, not sure of failure (previous owner). Now 52,000 miles and been MTM 568'd at same time as box replaced. G/Box service at 40,000 miles, all good, no issues so far, smooth as silk.
7. w8pmc - had 2 boxes go during ownership. 1st at about 15K miles & the car was stock (had only owned it about 2 months) Soon after i had the car tuned to Sportec/AmD Stage 2-3 & was putting out over 560BHP & lbsft & the box (mapped during tune) was fine through to 40K miles when it failed again. Sold the car soon after that.
8. p3u - clutch packs and tc went due to loss of pressure in system at ~91k miles. Stock other then Milltek Exhaust at the time.
9. Hartge (2004) MTM Stage 1 (ECU & TCU) @16k. First box failed at 35k, second at 49k
10. Golffather (previous RS6 saloon) 2003 - MRC Stage 1+, Milltek. Total failure at 54k miles.
11. GregRS6 2003 Bought it with a so called gearbox warranty at 84K. engine and box out again 86K
12. GardinerG (2003) Stock when gearbox went at 36k miles. West Tuned & touch wood all is fine at 63k. Gearbox Service in 2 weeks (fluid & filter etc)...
13. spurtle (2003) MRC Stage 1+, TC failed @ 50k miles. Will change ATF every 20k from now on.
14.Grizz-new box fitted at 80k , stage 2 car ..
15.Billiemapped new box fitted and remapped at 51k...
16. mrmule: Box #1 failed at 68k. Regular ATF flushes by MRC. Standard ECU.
17. JCviggen (2003) Stock, TC is gone at 65k. Never serviced.
18. Seanypeeps Standard.Full audi service history 2004 salloon.Gearbox fail at 39578K.
19. marv8 had a new gearbox supplied and fitted at 39167 had a "repair" due to gearbox oil leak at 40469 (issue with replacement maybe as seems too few miles???)
Now at 49k and TC failed, swarf in gearbox so rebuild with uprated drum and new clutch packs (plus a few other bits) Car standard AFAIK.
20. MalcolmSu (2004) Standard. Bought at 36k miles just turned 93k miles and gearbox failed cause yet to be determined. Never serviced AFAIK
21.stealthyspeeder (2003) stock - 84k miles - full audi service history (no gearbox service) - got a rebuild, was told that everything in the gearbox had burnt out
22. bam_bam (2003) 113,000 failing, only one GB service on this 'box, I think (before that see bookfather's comment at no. 10) - TC stuck open, slipping and occasional slamming into gear. Currently going through a WD debacle for a fix.

Never Failed
1. Dave (2003) MRC Stage 1+ at 80K, still going strong at 110K, box serviced at 80K
2. Gorwanvfr Standard power 39,000 mls still going strong (Never touched)
3. el_ringo (2003) STD until 55,000 mi (Oct08) CCode 1, a 'box service at 60,000 (Mar09) now at 75,000mi (Feb10)
4. CliveH (2002) AMD code since mid 06 55k, gearbox service at 60k (Oct06), still going strong at 90k
5. RS6Steve (2003) Standard 63K still okay (Gearbox full service 62k, No debris)
6.Shoppinit 75000 mls with no problems. ATF changed at 70k and will be at every service now. ATF was clear and clean.
7. Steve Cuz (2003) STD 77k, Gearbox ok, (2 gearbox services in 2009)
8. ecain63 - bought at 50k. MTM1 on ECU and TCU @ 51k. Box serviced every 20k since. Still tight as a Nunns chuff and hit 90k mark today.
9. RS6-4dr911 – 48k mi on original, MTM TCU at 35k, fluid changed at 40k, flushed at 46k, clean fluid on both, will flush every 20k hereafter, just now flashed ECU to Eurocharge Stg.1,
10. woodlum (2002) STD 48k, no probs and works fine, never been serviced, undecided as to service or not??
11. RS6_Dave (2003) Std til 27,500, then MRC Stage 1+ , box map with Service, MRC stage 2 @34k, no probs yet and just turned 40k.
12. MoRS6+ RS6plus, STD, 26k, original ATF, smooth as ice.
13. Bazza (2003) Oettinger remap on ECU/TCU @ 29K (2006) now 39k...fingers crossed all OK
14. Coullboy (2004) GregR1's old motor. Gearbox oil + Filter etc 57K(£360 Specialist cars Aberdeen) , seems to be fine. Engine Standard (59K now).
15. 500bhp (2003) Grizzed, CC Stage2 + TCU, Gearbox oil + Filter etc 95K. All fine
16. Knutts (2003), STD, 78k, no probs and never been serviced.
17. Robrs6 (2003) STD, 88K, Box serviced at 50K, still going strong.
18. C5NVS (2003) STD, 58k, owned since 55k and no clear evidence of service (FASH and considering Audi "lifetime" ATF stance, suspect no service), gearbox still drives like new.
19. Fizmo100 (2003) STD, 70k, Just bought, no apparent issues, but currently having a Unit 20 gearbox service just to be on the safe side!
20. jamesthecat (2003)STD 48k no probs but just waiting for atf oil from audi to service it.
21. jd_Hants (2003) Gearbox serviced 80K. MRC Stage 1+ @ 85K, 95K now
22. Condor24 .. May 2003 .. 46,000 miles to date .. I think serviced by Grizz February 2009
23. viffer. Standard, 72K. Gearbox service at 42K (Camberley Audi)
24. aka_dk (2004) STD, 103k, no problems, gearbox serviced at 101k
25. zip929 (2002) STD, 98K, no service and no probs.
No matter where you go, there you are.

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Re: Gearbox life survey

Post by HYFR » Tue Jul 26, 2011 11:17 pm

bam bam - comment number .10 is a different bookfather and a different RS 6

I think Darth had x2 gearbox services by the original bookfather

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