View Full Version : DIY Converter Swap
4everRS
July 10th, 2011, 23:42
Ok, it's really not a DIY thread, but I have a few pics. Pat made the journey up north this weekend and we swapped my TC out for an ACE rebuilt. It is quite a project and not for the faint of heart. Started the work Friday night at about 8pm and started packing up tools at about noon today (Sunday).
There was a time yesterday when we almost gave up. The god-damned bell-housing bolt behind the passenger side turbo was really frustrating.
http://i864.photobucket.com/albums/ab210/crocodile64/IMG_0559.jpg
http://i864.photobucket.com/albums/ab210/crocodile64/IMG_0563.jpg
http://i864.photobucket.com/albums/ab210/crocodile64/IMG_0564.jpg
We were able to use a friends shop, and Pat is invaluable for this. Obviously, there are guys out there (tozo) that do this all the time, but we hadn't done it before and I don't think we'd do it again. All seems to be running fine except for some slight surging under load. I think the TCU and ECU are still adapting and seems to be getting smoother the more I drive it.
MaxRS6
July 10th, 2011, 23:52
Wowza- You guys have balls of steel...
My engine/tranny is out at the moment with the turbos replacement project. However; I chose the "someone else do it" method..
Congrats on taking it on and gettin r done!
4everRS
July 10th, 2011, 23:59
Thanks Mad Max. More Pics.
Cradle out,
http://i864.photobucket.com/albums/ab210/crocodile64/IMG_0558.jpg
Flex Plate,
http://i864.photobucket.com/albums/ab210/crocodile64/IMG_0565.jpg
Bastard bolt location. It the one with the sleeve sticking out. Doesn't look tough from this angle!
http://i864.photobucket.com/albums/ab210/crocodile64/IMG_0566.jpg
bilko1
July 11th, 2011, 06:51
Nice job, i thought the turbo had to be removed to get to the bastard bolt.
hahnmgh63
July 11th, 2011, 06:58
So the question is....have you driven the car and can you tell a difference? I'm getting ready to install my TC & Tranny in over the next month (leaving in two weeks for two weeks) and hope to have it all done by early August. I've removed the SAI system and the Aux radiators. Can't wait to get it back on the road.
V8weight
July 11th, 2011, 14:11
Nice job, i thought the turbo had to be removed to get to the bastard bolt.
Moved aside more or less.
bilko1
July 11th, 2011, 17:07
Moved aside more or less.
Hey Pat, fancy a trip to the UK to show us how it's done :) everyone over here stills drops the whole lot.
V8weight
July 11th, 2011, 19:01
Hey Pat, fancy a trip to the UK to show us how it's done :) everyone over here stills drops the whole lot.
In retrospect, dropping the engine/ transmission as a module would probably be the quickest way to go. There's no turning back by the time the cradle is laying on the floor and there's one bolt left in the bell housing....
4everRS
July 11th, 2011, 19:12
In retrospect, dropping the engine/ transmission as a module would probably be the quickest way to go. There's no turning back by the time the cradle is laying on the floor and there's one bolt left in the bell housing.... I'm already having horrific flashbacks. I have an appointment with a shrink tomorrow.
4everRS
July 11th, 2011, 19:19
So the question is....have you driven the car and can you tell a difference? I'm getting ready to install my TC & Tranny in over the next month (leaving in two weeks for two weeks) and hope to have it all done by early August. I've removed the SAI system and the Aux radiators. Can't wait to get it back on the road. Well, I can't really give you a good answer right now. I haven't driven the car enough to get the TCU and ECU to play nice. There is still a little bit of line pressure variation, and slip-grabbing of gears upon changes. I was initially pretty nervous about this, but I brought it over to a local transmission guy late this morning to get his opinion, and have him drive it. He said that it is going to take a couple hundred miles for the TCU to adapt, and the odd shifting is very normal right after installing a new TC and having the battery disconnected for an extended period.
V8weight
July 11th, 2011, 19:28
I'm already having horrific flashbacks. I have an appointment with a shrink tomorrow.
Hahaha...I was a new level of exhausted last night..the last thing I remember was the storm sirens going off...woke up this morning and there were trees down everywhere. I never batted an eye.
4everRS
July 11th, 2011, 19:31
Hahaha...I was a new level of exhausted last night..the last thing I remember was the storm sirens going off...woke up this morning and there were trees down everywhere. I never batted an eye.Yikes, must have been the storm that went through here.
ttboost
July 12th, 2011, 00:45
Congrats. Welcome to the club....I opted to remove the whole engine/trans combo for my TC job. After doing it once (actually twice), I would never consider doing it any other way. The ONLY down side is that you have to drain more fluids...it's a pain, but WAY more room to work...and more opportunities to replace stuff...I don't recall mine having any learning time though? Ran great out of the gate?
4everRS
July 12th, 2011, 03:26
I hadn't realized that you did this job yourself Mike. No learning time huh? I assume you had your battery disconnected for the job? The more I've been driving it, it seems to be getting better.
How many quarts of ATF did yours take?
Congrats. Welcome to the club....I opted to remove the whole engine/trans combo for my TC job. After doing it once (actually twice), I would never consider doing it any other way. The ONLY down side is that you have to drain more fluids...it's a pain, but WAY more room to work...and more opportunities to replace stuff...I don't recall mine having any learning time though? Ran great out of the gate?
hahnmgh63
July 12th, 2011, 04:18
I would think about rechecking your fluid level after the T.C. replacement. Who knows if it takes some times to get all of the air out of the system if you had the tranny & TC out of the car.
ttboost
July 12th, 2011, 11:26
I hadn't realized that you did this job yourself Mike. No learning time huh? I assume you had your battery disconnected for the job? The more I've been driving it, it seems to be getting better.
How many quarts of ATF did yours take?
I think between 3-5 qts? Total pain to do. I pulled the whole motor, and yes disconnected the battery...When put it back in, I went to start it and POOF...wisp of smoke. I forgot to connect the ground wire from the chassis to the block (by the starter). That little OOPs blew a hole in my turbo coolant line...SOOOOO everything back out..fixed it and put it all back in...Been running mint since....
I would think about rechecking your fluid level after the T.C. replacement. Who knows if it takes some times to get all of the air out of the system if you had the tranny & TC out of the car.
Haven't checked it since....We couldn't push anymore n and if it's not leaking...it's still in there...
4everRS
July 12th, 2011, 13:06
I would think about rechecking your fluid level after the T.C. replacement. Who knows if it takes some times to get all of the air out of the system if you had the tranny & TC out of the car.
Thanks Mark, think I will do that. I also pm'ed tozo and he said that I am probably 1.5 quarts low.
Mike, you were able to get 3-5 quarts in the converter before install? Any idea on how much the whole system took?
Can anyone verify the capacity? 13 quarts?
ttboost
July 12th, 2011, 14:00
Thanks Mark, think I will do that. I also pm'ed tozo and he said that I am probably 1.5 quarts low.
Mike, you were able to get 3-5 quarts in the converter before install? Any idea on how much the whole system took?
Can anyone verify the capacity? 13 quarts?
I was lazy when I did this one. I did NOT put any fluid in the TC when I put it in. My guy said as long as I don't drive it, it won't hurt it. After we got it all together, got it running, we jacked it up on the lift, unscrewed the cover and started pumping fluid in. I want to say we put about 5qts in, maybe 6, probably not 4...don't really recall. If it's running and you can't put any more in, you're done. I don't think you can be low after that..unless you leak somewhere...
V8weight
July 12th, 2011, 15:18
When I filled Kyles transmission, despite running out of the drop tube at exactly 35C, the fluid was slightly aerated, probably due to filling an empty system. I put 1 quart in the converter to start with, and it took an additional 11 quarts to fill the system. My guess is that as the air has worked itself out of the fluid, the level has dropped. There's nothing I could have done about it at the time. When the fluid temp reaches 35C, it's over, and the plug goes back in. I would say that refilling an empty system should be done in two stages for this reason.
lswing
July 12th, 2011, 19:00
My mechanic just did the new A.C.E. built TC on mine, running smooth right out of the shop. Also did all the sensors down there, new tranny fluid, rear seal and drive shaft. I could notice the extra power going to the wheels for sure! Also the shuddering under load has all but gone. I do seem to notice a few small "bumps" when accelerating hard under load uphill, on the flats it's a smooth as glass as the RPM's just roll up to the red. MTM chip goes in Thursday, can't wait! Thanks for posting the pics and details of your TC swap, hope it adjusts there. Not sure if mine is a bit smoother because of the Revo tune?
4everRS
July 13th, 2011, 03:55
Anyone know the capacity of a dry TC and tranny for the beast????
4everRS
July 13th, 2011, 18:44
I've got good news and bad news on this situation. Good news is that we found the likely cause of the funny shifting. There was also a very faint humming/buzzing noise under load. The O-ring seal that goes from the tranny filter to the valve body wasn't installed, so its cavitating and causeing the oddities.
Bad news is that I feel like an ass clown because I did it.
MaxRS6
July 13th, 2011, 18:50
Congrats on finding the root issue..
Players taking swings are bound to have strike outs. The spectators just get splinters up their a$$. I give you props again for taking on the task (albeit with the Pat safety valve)..;0
4everRS
July 14th, 2011, 04:01
More good news, the seal is in and things feel very good.
hahnmgh63
July 14th, 2011, 04:34
Congrats on finding the issue, and your new TC and the tranny both just got a quick flush so you should be good for a while to come. P.S. I'm trying not to jinx you but knock on wood anyways just to be sure.
ttboost
July 14th, 2011, 11:30
More good news, the seal is in and things feel very good.
It's always a good idea to check your trans filter anyway, even if you don't change it. When my car came in, the guy traded it in because the tranny started acting funny...shifting hard...banging,etc... my buddy (who is the mechanic there) got it up on the lift, dropped the pan, didn't see anything wrong, but CHANGED the filter, as he was in there. Took it for a test ride and PERFECT?! Came back to the shop and gave the old filter a closer inspection and it had a small split right on the seam you could barely see...
DHall1
July 19th, 2011, 03:01
Glad to hear it all worked out.
I've got good news and bad news on this situation. Good news is that we found the likely cause of the funny shifting. There was also a very faint humming/buzzing noise under load. The O-ring seal that goes from the tranny filter to the valve body wasn't installed, so its cavitating and causeing the oddities.
Bad news is that I feel like an ass clown because I did it.
4everRS
July 19th, 2011, 03:37
Me too. Still shifting great (knocking on wood Mark). Good to finally get on the gas a little. Also have a Vag-Com on the way finally to get some logging done. Work has turned to installing the Meth injection kit. Yee-Haw
Glad to hear it all worked out.
AUDI5000CSTQ
July 19th, 2011, 06:42
One word...Fidelity
But wow what a job you both undertook, great for you. Glad the problems got worked out.
V8weight
July 19th, 2011, 14:11
One word...Fidelity
But wow what a job you both undertook, great for you. Glad the problems got worked out.
Haha...It's funny, every thing that my Zurich warranty has covered on my car, I've ended up fixing on Kyle's car anyhow...