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New W8 Owner

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Uberhare View Drop Down
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  Quote Uberhare Quote  Post ReplyReply Direct Link To This Post Topic: New W8 Owner
    Posted: 05-Feb-2018 at 03:40
So far the problem has not come back. It cleared itself the next time I started it, so I reset the codes. I imagine it will come back eventually.
04 Passat W8 Wagon,10 A3 TDI, 05 Passat TDI Wagon (6spd M/T), 93 Corrado VR6
89 VW LT31 Florida, 89 Vanagon Whitestar, 67 Beetle Limo, 64 PA28-140
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  Quote GS535i Quote  Post ReplyReply Direct Link To This Post Posted: 05-Feb-2018 at 00:15
The 'shock therapy' is a good deal, and frequently works ----- until you find one of the 4 solenoids that is obviously stuck - no 'click'.

At that point, it is not much more work to pull the valve cover and remove the offending solenoid for a cleaning & flush of the bore.

Did this once w. success, described herehttp://www.w8forum.dk/forum_posts.asp?TID=5457&KW=&title=camshaft-adjuster--p0021-fix-success

Edited by GS535i - 05-Feb-2018 at 00:18
03 Variant W8 silver on black TIP
00 Variant white 1.8T 5sp
96 993 C4S midnight blue/cashmere
90 535i blk/blk 5sp
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  Quote JayTheSnork Quote  Post ReplyReply Direct Link To This Post Posted: 30-Jan-2018 at 04:48
which cam adjuster is the impossible one to get unless you pull the engine?


Edited by JayTheSnork - 30-Jan-2018 at 04:48
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  Quote Uberhare Quote  Post ReplyReply Direct Link To This Post Posted: 28-Jan-2018 at 23:16
Made it 2500K now. Cam position fault bank 2 just came on. Guess I'll be trying the "shock therapy". If not at least I have a parts engine.
04 Passat W8 Wagon,10 A3 TDI, 05 Passat TDI Wagon (6spd M/T), 93 Corrado VR6
89 VW LT31 Florida, 89 Vanagon Whitestar, 67 Beetle Limo, 64 PA28-140
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  Quote Uberhare Quote  Post ReplyReply Direct Link To This Post Posted: 28-Dec-2017 at 04:45
All good 2nd time around. It's a beast in the snow!   Under 20 hours the 2nd time around....

Edited by Uberhare - 28-Dec-2017 at 04:47
04 Passat W8 Wagon,10 A3 TDI, 05 Passat TDI Wagon (6spd M/T), 93 Corrado VR6
89 VW LT31 Florida, 89 Vanagon Whitestar, 67 Beetle Limo, 64 PA28-140
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  Quote Uberhare Quote  Post ReplyReply Direct Link To This Post Posted: 23-Dec-2017 at 23:58
First rebuild was purchased so I wouldn't have to do this a 2nd time! Figured out afterwards I was given a TDI converter (& it slipped), so I got my original one back but rebuild. Fingers crossed! I'm hoping to finish it tomorrow just in time for Christmas.
04 Passat W8 Wagon,10 A3 TDI, 05 Passat TDI Wagon (6spd M/T), 93 Corrado VR6
89 VW LT31 Florida, 89 Vanagon Whitestar, 67 Beetle Limo, 64 PA28-140
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  Quote GS535i Quote  Post ReplyReply Direct Link To This Post Posted: 23-Dec-2017 at 23:45
That's fast - assume that there must be an interesting story on the 2nd TC rebuild ;) .... what was done differently to avoid a 3rd teardown?

BTW, Best of the Season!!
03 Variant W8 silver on black TIP
00 Variant white 1.8T 5sp
96 993 C4S midnight blue/cashmere
90 535i blk/blk 5sp
928 5sp
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  Quote Uberhare Quote  Post ReplyReply Direct Link To This Post Posted: 22-Dec-2017 at 03:43
After taking a few weeks off from this I'm back at it.   7.5 hours so far and it's just about ready drop back into the car. Another hour of tinkering and it should be back in the bay.
04 Passat W8 Wagon,10 A3 TDI, 05 Passat TDI Wagon (6spd M/T), 93 Corrado VR6
89 VW LT31 Florida, 89 Vanagon Whitestar, 67 Beetle Limo, 64 PA28-140
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  Quote Uberhare Quote  Post ReplyReply Direct Link To This Post Posted: 02-Dec-2017 at 01:26
So my story does not end here....After driving the car long enough to warm up the fluid this happened:

1 Fault Found:
17125 - Torque Converter Clutch
            P0741 - 35-00 - Stuck OFF / No Power being transferred

Lovely. After reading about the captive clutch on this unit, no wonder it is so problematic. Some info can be found here on the Sonnex website: https://www.sonnax.com/tech_resources/57-revisiting-the-captive-clutch

0.040" of movement in the spring plate with 0.030" of material (friction surfaces). After 0.010" of wear the lockup no longer works. I am quite surprised no one has come up with a replacement/better spring plate for this unit. I talked with a local European transmission specialist and he tells me very few re-builders can get this one right every time. I bet that plate gets worn and fatigued causing much of the rebuild problems. It doesn't seem to be available either.

If I had not driven the parts car I would have blamed the valvebody and been tearing into it right now.   So, out to the shop for round 2.......



Edited by Uberhare - 02-Dec-2017 at 01:35
04 Passat W8 Wagon,10 A3 TDI, 05 Passat TDI Wagon (6spd M/T), 93 Corrado VR6
89 VW LT31 Florida, 89 Vanagon Whitestar, 67 Beetle Limo, 64 PA28-140
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  Quote Uberhare Quote  Post ReplyReply Direct Link To This Post Posted: 30-Nov-2017 at 23:11
Lots of items that are different....I'd pretty much need a parts car:

Driveshafts (x3)
flywheel/clutch
shifter assembly
cooler lines
pedal/hydraulics etc

I've done this on a TDI Passat in a day (albeit a very long day), but it was pretty straight forward on that car. I'll just live with the auto for now unless a parts car pops up for the right price. I could probably do the swap using B5 S4 parts too.
04 Passat W8 Wagon,10 A3 TDI, 05 Passat TDI Wagon (6spd M/T), 93 Corrado VR6
89 VW LT31 Florida, 89 Vanagon Whitestar, 67 Beetle Limo, 64 PA28-140
Back to Top
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