Auto Trans gave up the ghost

[dorje]

So I finished up the 2.2 Subaru conversion. The big news now is that the automatic transmission is not shifting past 1st gear. Occasionally I can get it into second by revving the engine, but not reliably.

Dropped the pan. Full of metal shavings. Looks like my clutch bands at least are complete toast. The ATF smells burnt.

And yes, I did just about everything that you're not supposed to do if you want to keep a transaxle in good working order: I overfilled it with ATF (Type F at least), had an old IAC that was stuck open so starting torque was way too high, and I decided it was a great idea to load the van full of firewood and take the direct route up to my house.. something like a 15 degree incline.

So I was stupid, the new powerful engine was too hard to resist, and I burnt it up. What now?

* Get it rebuilt
Buslab recommends a place off Broadway in Oakland, though not with stellar reviews. I hear people say great things about German Transaxle. I'm worried about shipping cost though.

* Rebuild it
1. Time: Will it take a long time for a transmission newbie? I would hate to screw something up, or have to re-drop it 5 or 6 times.
2. Space: I managed to rebuild the Subaru engine on the floor in my garage, but I'm thinking I'll at least need a decent workbench. Good excuse to build one, but wife is starting to ask for time estimates.. she's got me pretty booked up through the summer. And I was hoping for a van trip in there too.
3. Parts: Is there a simple master list of parts needed for rebuild, or is it more like, see what's worn out and order new X?
4. Kids: If it takes a long time with many parts laid out on my (hopefully) workbench, the probability of the 2-year-old coming and grabbing a friction plate or something rises with each day I leave the stuff out there.....

What do you guys think?

[ThankYouJerry]

I may be an exception, but I didn't have the best luck with my rebuilt GTA auto trans + turbo option (3rd started slipping in less than 1500 miles from new). For another thing, GTA does not warranty their rebuilt auto transmissions if they are bolted to anything other than a stock WBX. Read the fine print.

If I had to do it over again, I'd use the trans shop in Sacramento that Stephan's Auto Haus uses or I'd go with an auto trans from Salim at Country Homes Campers. BTW, Salim also sells a great auto trans cooler (with a fan) as well as 3.73 R&Ps which would be a perfect match for your Subie 2.2. You can buy those items from CHC independently of a trans if you decide to go with a different shop for the rebuild or DIY.
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1990 Multivan - "Ohana"
1.8T, Auto w/3.27 R&P + Peloquin TBD

[kourt]

For the "you rebuild it" option, see:

http://www.thesamba.com/vw/forum/viewtopic.php?p=7835491#7835491

kourt

[Wildthings]

Buy a rebuilt exchange from a reliable builder and get it over with in a day. I wouldn't recommend going with a longer gearset or you will just be right back to where you started with the original WBXer engine as far as tractive effort at lower vehicle speeds and will be putting additional stress on the automatic section of the transaxle.

If you don't replace your final drive section then you should at least have it resealed at this time.

[djkeev]

Well..... You get HUGE points for brutal honesty..... "I abused it horribly and it broke”.

Now if I were a rebuilder I would shy away from selling you one but what they don't know isn't going to hurt them is it?

These aren't difficult units but care, attention to detail and extreme cleanliness are called for.

Keep us updated!

Dave
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Stop Dead Photo Links how to post photos

Ghia
http://www.thesamba.com/vw/forum/viewtopic.php?t=392473

Vanagon
http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537

Beetle
https://www.thesamba.com/vw/forum/viewtopic.php?t=482968&highlight=74+super+vert

[dorje]

Come on, I'm great business for a rebuilder! Although now I'm learning a bit about proper care & feeding for an auto trans.

I really like the sound of "get it over with in a day"! And I figure I have years to mess with longer gearsets and LSDs etc... right now I just want my Westy running.

That place in Sacramento sounds good, maybe close enough to run it out there and save on shipping. I'll call Stephan's Auto Haus and get the recommendation unless you happen to recall the place's name @ThankYouJerry?

Country Home & Campers looks really pro, and yeah their transmission cooler looks great -- though I already went with the GW trans cooler since as a total newbie I was just following whatever Buslab's suggestions were. San Diego might be far to drive though, especially with a monstrosity in the back of the car

[Merian]

you will want one of the hot rodded trannys with Audi parts - you can get that place in Bend to build one IIRC, or you can follow kourt's directions

to drive the Van during the interregnum, put n a working regular unit, then sell it after swapping in the Audi-fied unit

obviously, you'll need some cash up front

[dorje]

BTW @kourt your Audi rebuild writeup was extremely inspiring, and the only reason I was even considering rebuilding it myself. I even did a search of local salvage yards to see if they had any Audi's of the correct vintage... But yeah, I'm getting an interim trans professionally rebuilt & see how long I can last until making one with Audi internals.

More to the point, I gave back the cherry-picker and the floor jack I was using when doing the engine swap. What's the minimum of tools that I'm going to need to easily drop the transaxle?

I liked the rig with a winch mounted to some 2x4's:
http://www.thesamba.com/vw/forum/viewtopic.php?t=643378
http://www.harborfreight.com/2000-lb-capacity-geared-winch-5798.html

This doesn't look bad either:
http://www.harborfreight.com/1000-lb-capacity-engine-support-bar-96524.html

Here we're getting expensive but "adjustable tilt saddle" is sounding nice compared to my last time trying to balance the transmission on a floor jack..
http://www.harborfreight.com/800-lb-Low-Lift-Transmission-Jack-69685.html

Folks are saying any ATV jack makes the job pretty easy.

Is there a secret to getting the transaxle off without dropping the engine? It'd be nice to not have to drain the coolant etc.

[borninabus]

it's no secret.
the trans can be easily removed while the engine is supported by a 2x4 and a bungee.
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88 Van WBX, A/T - 13 JSW TDI 6M/T - 2012 Touareg TDI Sport

[dorje]

Bungies and 2x4's.... wow

[ThankYouJerry]

[ThankYouJerry]

[dorje]

So the place Stephan's uses is Pro Built Transmission in Sacramento, said $2200 P&L.

Sounding pretty good, plotting to secretly buy a core, do a Audi rebuild, and sell the stock rebuilt transmission......! 'Course there are plenty of van projects that may take precedence, like that aux battery, decent interior lighting.....

Looking at getting a used ATV jack now.

[ThankYouJerry]

^^^ Good choice. Let us know how it turns out!
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1990 Multivan - "Ohana"
1.8T, Auto w/3.27 R&P + Peloquin TBD

[danfromsyr]

Quick question, HOW IS YOUR THROTTLE CABLE/PEDAL HOOKED UP to the THROTTLE BODY & TRANSMISSION RELAY LEVER? what did you do to make it all work properly. the AT relay lever must move with throttle movement to not overly slip the clutches.

[Wildthings]

[chachi]

for the record, GTA will warranty a WBX built up to a 2.4. or at least that's what they told me. doesn't help you subaru guys but they're giving us a warranty on our RJE 2.3. we'd already bought ours and delivered it to walla walla before i started hearing horror stories about GTA and non-stock engines and am now appropriately nervous. but every time i talk to them i make sure, for the umpteenth time that we do have that magic warranty. they always say yes, sooooo...
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'74 transporter panel
'91 vanagon carat NAHT

[ThankYouJerry]

[dorje]

To answer @danfromsyr's question, I'm using Burley's throttle conversion kit so I can use the stock VW throttle cable and kickdown lever.

http://burleysmotorsports.com/index.php?main_page=product_info&products_id=4

(It doesn't mention it anywhere on the internet but you have to cut the firewall a bit to get it to fit, so if you use that kit try to do that before you mount the engine, unlike me.)

Curious, what would I look for to make sure everything is adjusted properly? Is it described in the Bentley?

[danfromsyr]

the effect of the throttle connection to the AT input relay lever is that it effects when and how the AT shifts. and if not connected at all or installed incorrectly. it can create such soft shifts that you burn the clutches and then more if you don't get it re-mediated in time. it will hold the 1-2 shift till a higher mph, which is a pain in town traffic. we had this oversight with my brothers I5 turbo swap.
procedure is in the Bentley

so you have the kickdown rod hooked from the AT relay lever to the subie throttle body?

I don't see where Burley kit is actually for an automatic,