New W8 Owner

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   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 :)

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Uberhare Members Profile Send Private Message Find Members Posts Add to Buddy List Newbie Joined: 16-Nov-2017 Online Status: Offline Posts: 37	Quote Reply 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

JayTheSnork Members Profile Send Private Message Find Members Posts Add to Buddy List Admin Joined: 20-Mar-2016 Location: Waterford, CT Online Status: Offline Posts: 141	Quote Reply 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.

Uberhare Members Profile Send Private Message Find Members Posts Add to Buddy List Newbie Joined: 16-Nov-2017 Online Status: Offline Posts: 37	Quote Reply 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

Uberhare Members Profile Send Private Message Find Members Posts Add to Buddy List Newbie Joined: 16-Nov-2017 Online Status: Offline Posts: 37	Quote Reply 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

eddycooper Members Profile Send Private Message Find Members Posts Add to Buddy List Groupie Joined: 24-Aug-2014 Online Status: Offline Posts: 68	Quote Reply 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.

Uberhare Members Profile Send Private Message Find Members Posts Add to Buddy List Newbie Joined: 16-Nov-2017 Online Status: Offline Posts: 37	Quote Reply 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

Uberhare Members Profile Send Private Message Find Members Posts Add to Buddy List Newbie Joined: 16-Nov-2017 Online Status: Offline Posts: 37	Quote Reply 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

Uberhare Members Profile Send Private Message Find Members Posts Add to Buddy List Newbie Joined: 16-Nov-2017 Online Status: Offline Posts: 37	Quote Reply 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

GS535i Members Profile Send Private Message Find Members Posts Add to Buddy List Groupie Joined: 02-Aug-2011 Location: Nova Scotia Online Status: Offline Posts: 62	Quote Reply 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

Uberhare Members Profile Send Private Message Find Members Posts Add to Buddy List Newbie Joined: 16-Nov-2017 Online Status: Offline Posts: 37	Quote Reply 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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