Announcement

Collapse
No announcement yet.

Crash course in 5HP-19FL surgery mit pics

Collapse
X
Collapse
 
  • Page of 2
  • Filter
  • Time
  • Show
Clear All
new posts
Previous 1 2 template Next
  • #1

    Crash course in 5HP-19FL surgery mit pics

    **disclaimer, I know this is a Porsche trans, however since there's next to no info on the 5-HP19's I would request to the mods that this be left in the Bavaria forums since it's exactly the same trans configuration as an A4/A6/A8/S4/Passat/BMW automatic.**

    So in the spirit of crazy repairs, I've decided to take apart the valve bodies on my folks Boxster. It was slamming into gear while coasting on tiptronic 4-3 downshifts. I think it's an issue with the C clutch accumulator piston. I got the go ahead to pull it apart and see if anything's amiss. I spoke to one of the ZF trans shops in Calgary (Mister Transmission) and I may end up getting a rebuild kit for it since I'm into it this far.

    I'll admit it's unnerving pulling apart valve bodies on a $6000 transmission. So I've been taking my time on this one. I figure if I just stay as meticulous as I can and as patient as I can then it should turn out OK (knock on wood).

    I'm taking plenty of pics to reference later, so I figure I'll keep a running tab on my progress.

    Here's the patient


    Here's the operating room


    Pics of the disassembly








    More to come...

    Here's the rest of it













    I lied, here's more




    Here's the bad rubber damper


    Here it is in the valve body


    Here's the C clutch accumulator bore




    Assembly


    My spring compressor


    My other spring compressor, this is done extremely lightly BTW

    Putting the plate on

    Doweling it in place with 3 bolts

    Voila!





    The remains of it's 9 liter fluid bender

    Here she is alive and well!
    Last edited by Mister T; 08-04-2010, 07:38 PM.
    "Paranoia is just the eerie sensation of knowing you're right"
    Tags: None
  • #2
    Re: Crash course in 5HP-19FL surgery mit pics

    There we go, the entire valve body assembly is apart. Now all that remains is the part with the check valves and orifices. I'll probably wait until Monday for that part.
    "Paranoia is just the eerie sensation of knowing you're right"

    Comment

    • #3
      Re: Crash course in 5HP-19FL surgery mit pics

      This scares me. Nice labeling system though. I bet that saves you in the end.
      Jess

      2010 Jetta TDI 6 SPD - Stock Comfortline model

      Comment

      • #4
        Re: Crash course in 5HP-19FL surgery mit pics

        Originally posted by luunta View Post
        This scares me.
        At least that makes two of us The part that has me the most intimidated is the part under the plate with all the check balls, springs and orifices. I saw good idea on line for that one though. You take the plate, trace the outline and all the holes where any inserts go. Then, as you pull anything out, you place it on the paper and label it as you pull it out.
        Last edited by Mister T; 07-18-2010, 11:47 AM.
        "Paranoia is just the eerie sensation of knowing you're right"

        Comment

        • #5
          Re: Crash course in 5HP-19FL surgery mit pics

          So my curiosity got the better of me and I decided to pop the top off the section with the check balls, springs and orifices. I haven't pulled any out yet though, as I'm still waiting on the rebuild kit.
          "Paranoia is just the eerie sensation of knowing you're right"

          Comment

          • #6
            Re: Crash course in 5HP-19FL surgery mit pics

            GL!!

            Cool project!
            Find me on Instagram @pry4sno

            Candy White 2010 VW Golf Sportwagen TDI 6 speed /// #farmenwagen
            Indigo Pearl Effect 1992 80q 20v /// Eventual AAN'd Winter Sled
            Brilliant Black 1990 Coupe quattro /// Because Racecar

            Comment

            • #7
              Re: Crash course in 5HP-19FL surgery mit pics

              is this a "You break it you buy it" deal?
              Jess

              2010 Jetta TDI 6 SPD - Stock Comfortline model

              Comment

              • #8
                Re: Crash course in 5HP-19FL surgery mit pics

                I'm thinking more along the lines of "I break it, I flee to Mexico" kind of deal.

                However I'm still waiting on Chris at Mr Transmission to get back to me on the rebuild kit. I'm going to have to call tomorrow and shake his tree to see what's up. I'm getting a little antsy to know if this is going to work or not.
                Last edited by Mister T; 07-21-2010, 09:24 PM.
                "Paranoia is just the eerie sensation of knowing you're right"

                Comment

                • #9
                  Re: Crash course in 5HP-19FL surgery mit pics

                  i'm getting stressed just looking at the pics! Hope it all works out well for you!
                  Stefan
                  -> '19 Deep Black Pearl Alltrack
                  -> '05 Urban Grey Passat Wagon TDI.
                  -> Past rides: '14 Allroad, 06 Mazda5, '98 Jetta K2, '01 Jetta TDI, '91 Mazda B2200, '81 Toyota Cressida
                  -> FutuRe Ride...??!

                  Comment

                  • #10
                    Re: Crash course in 5HP-19FL surgery mit pics

                    Want to rebuild my vans tranny lol
                    Name: Brent
                    His: '04 TDI Golf Mods: None If it's smoken it ain't broken
                    Family: '15 Jetta Sportwagon
                    Fun car: '92 Blue Karmann Crabby Cabby Mods: Coils, front and rear swaybars, LED interior lights and some other old things.

                    Comment

                    • #11
                      Re: Crash course in 5HP-19FL surgery mit pics

                      LOL I don't know, let's see if I can rebuild this one first (bang on wood)
                      "Paranoia is just the eerie sensation of knowing you're right"

                      Comment

                      • #12
                        Re: Crash course in 5HP-19FL surgery mit pics

                        So long time with no update, I figured I'd keep you guys posted. After getting off the phone with Steve at ZF North America (who was incredibly helpful BTW) it looks like my theory about the deformed rubber damper in the valve body being part of the problem was right on the money. Apparently, they function as dampers for the hydraulics during shift overlap. When they get pounded over time they deform and throw things off in the hydraulic actuations.

                        Also, it's possible that the bore on the C clutch accumulator is worn. I have yet to confirm that though. I've posted the pics in the first post.
                        "Paranoia is just the eerie sensation of knowing you're right"

                        Comment

                        • #13
                          Re: Crash course in 5HP-19FL surgery mit pics

                          So Steve emailed me back with some felpful facts that I thought I'd post up here in case anyone is interested. Also, it looks like the valve was chattering in the C clutch bore so I might be having to change that portion as well.

                          I have attached the 5HP19FL section of our valve body guide as well as a clutch and solenoid chart. There are a couple of comments in the thread worth elaborating on. All ZF products have an identification tag attached. This tag has what is called the catalog or engineering number. Matching numbers are identical transmissions and can be interchanged. Differences can be in number of clutches per pack, converter stall or design, differential ratio changes or updates to existing components that require new cataloging. I do have the ability to compare any two transmissions side by side for changes. It should also be noted shift quality, shift timing and even the function of the Tip are computer controls. Programming changes in the TCM have reduced production costs by allowing identical transmissions to behave differently. Some comment was made on clutch clearance checks, yes the clearance is important and controlled in most clutches by the thickness of the snap ring. This can be seen at the rear of our catalog in the snap ring selection guides. If you do have to venture into the transmission in most situations the factory has set the clearance and reusing the original snap ring dimensions will work well.
                          Last edited by Mister T; 07-28-2010, 12:47 PM.
                          "Paranoia is just the eerie sensation of knowing you're right"

                          Comment

                          • #14
                            Re: Crash course in 5HP-19FL surgery mit pics

                            Ladies and Gentlemen, she lives!!! I just got everything buttoned up, took her for a test run and she shifts flawlessly. What I wanted to do with this is to show that these valve bodies are not impossible to work on. I know there are people on the forums with tip issues that may be valve body related. Point is, you can work on these valve bodies. All you need is some time, patience and logical thinking.

                            I have way more of these pics on my computer if anyone is interested in pulling one of these apart. PM me and I can see about burning them to a disk and sending them to you.
                            "Paranoia is just the eerie sensation of knowing you're right"

                            Comment

                            • #15
                              Re: Crash course in 5HP-19FL surgery mit pics

                              those pictures still scare the **** out of me

                              Comment

                              Previous 1 2 template Next
                              Working...
                              X