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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: 26-Nov-2017 at 00:59
My parts car has that "feature".   I actually bought a replacement temp sensor, but grabbed the wrong one of the shelf.   I expected it to be the green one, not grey. Maybe next time :)
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 JayTheSnork Quote  Post ReplyReply Direct Link To This Post Posted: 26-Nov-2017 at 03:56
fans running all the time can also be caused by the front CTS being bad; been there and resolved it.
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  Quote Uberhare Quote  Post ReplyReply Direct Link To This Post Posted: 26-Nov-2017 at 05:26
It's back on all it's mounts!

20171125_213023 by uberhare, on Flickr

This little guys were a PITA:

20171125_115502 by uberhare, on Flickr

Fixed the downpipe while it was apart:

20171125_161615 by uberhare, on Flickr

Guess I'll be doing some A/C work too:

20171125_213532 by uberhare, on Flickr

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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Uberhare View Drop Down
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  Quote Uberhare Quote  Post ReplyReply Direct Link To This Post Posted: 28-Nov-2017 at 23:34
It's ALIVE AND WELL!   

A few more gremlins along the way:

20171126_152623 by uberhare

This next one was the real kicker....I damaged the speed sensor wires during the divorce of engine/transmission and had to repair the connector at the bottom. I assumed it was a bad splice and spent considerable amount of time redoing that repair first. Like laparoscopic surgery with it in the car! Found the corrosion at the ECU when I was going to pin it out. Cleaned up everything and she came to life!

ECU_wires by uberhare

What's in my driveway right now:
PassatCollection by uberhare

Passat_Outside by uberhare

9 litres of trans fluid
8.5 litres of oil
16 litres of coolant
1 litre of p/s fluid (and another one later to flush out the wrong fluid that was in there)

What an adventure, I would NOT want to do it again. I could have probably converted it to a TDI in less time.   It drives really nice now, but I am underwhelmed with the performance. I expected more to be honest, it's not much faster than my 6spd manual TDI @ 25PSI.   It would be nice to drive another one to see if it's where it should be.   Looking for a 6speed manual now for it. I've decided I don't like the automatic after all the work.


Edited by Uberhare - 28-Nov-2017 at 23:35
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 eddycooper Quote  Post ReplyReply Direct Link To This Post Posted: 30-Nov-2017 at 18:38
A manual swap isn't as straightforward as it should be for these cars:
- Final drive ratio is different. So you'd either need to change the front diff in your new 6-speed (not easy) or take the rear diff from your parts car too.
- If you get a 6-speed from another W8 it'll have an oil pump and lines that got a cooler in the radiator. Might easier to get one from another car without the oil pump.
- Exhaust piping is different. Might just be a difference of support locations, but for some reason there are different part numbers.
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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
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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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