More tranny problems...

[5150DSM]

Aloha,
I have a 92 TSi AWD 94,XXX miles. I already know my 2nd gear synchro is bad and I have ordered the new 1-2 kit from TRE. Yesterday my tranny really started acting up... In 1st the RPM's will wind all the way red-line(if I push it) and the car will not accelerate over 15mph, I shift into 2nd and it's still winding up the revs and accelerating very slowly... Once I get to 3rd there is no problem, I can drive in 3-4-5 all day without issue but I can barely get there. Sometimes I can feel slipping in the drivetrain and there will be a loud clunk as 1 or 2 engages. Also when I am just rolling up to a light in nuetral I can hear a grinding sound...It sounds exactly like a rotor rubbing but it's not. Please help, this is getting out of hand. I am planning on a rebuild but I would like to know what exactly is wrong before I take it to the shop. Thanks in advance for any help I can get.
Tony

 

[PogiTSI]

hmmm, Have you had ur clutch replaced????? how many miles are on the one you have now??? Does it grab high off the floor????


Actualy, That wouldnt explain the Slugish pull, it could be a number of things. maybe the motor is gone, not to scare you, do a compression and Leak down. are you burning any oil????

 

[92redman]

The first problem sounds like the clutch is slipping.

The grinding noise sounds like a bearing. Does it only grind when you are moving, or does it make the noise if you are sitting still and press in on the clutch?

If you are just sitting still, it is most likely the throwout bearing.
If it's while you are moving, it is probably a differential or output shaft bearing.

 

[spoolints04]

Actually, it sounds more like you broke the center diff. The spider gears inside the center diff like to break and get all in the other gears and bearings. This is the grinding noise you are hearing. Yes it feels like a clutch sliping because now that the diff is broke you not powering the rear wheels and you are relying on the viscous coupling to get the power to the front wheels. I'll bet this tranny is pretty much toast. Damn that sucks, cause 92 trannys are the best one's.

 

[5150DSM]

Thanks for the insights. Actually, after having bled the clutch cylinder, we are looking at throwout bearing and/or slave fork. Also the slave cylinder piston is very slow to retract leading me to believe that it may need replacement as well. The clutch is an exedy 2100lb with just about 500 miles on it. It was replaced just before I bought the car so I have no way of knowing whether the install was done correctly. Also, we found a small crack in the transaxle housing which may be contributing to the overall problem. Is that particular housing replaceable or is it necessary to replace the entire assembly?? Well, I am replacing the slave cylinder right now and preparing to check the slave for and throwout bearing. Any more insight and/or suggestions would be very appreciated.
Thanks Again,
Tony

 

[5150DSM]

Please help...
I am running out of ideas and things keep getting worse. There is a lot of clunking coming from the tranny and/or axles. Half the time if I ease out the clutch in 1st it grabs fine and I am able to drive normally. All the other times I start to roll and then there is a either a clunk and/or a sensation of locking up in the front wheels. From there it's as I described above... Engine revs up but there is no acceleration in 1st, 2nd, and now 3rd. If it was the center dif, I would have the problem ALL of the time, right? I am still leaning towards slave fork and/or throwout bearing but I would like to have some better info before I start getting into dropping and pulling apart the tranny. Anything you guys can offer would be much appreciated. Thanks again for any and all help.
Tony

 

[92redman]

Okay, I see what you are trying to describe now.

What it sounds like is you have a few gears with stripped teeth. Most likely the gears that you say don't work. I am not saying that is exactly the problem, but from what you describe, that is my best guess. I had the same thing happen to me, but it was with a transmission that was not shimmed proberly. I had a bearing blow apart and it tore up half of the teeth on first gear.

I don't want to say it is a common problem, but it does happen. If that is infact the problem, you pretty much need an entire tranny since you said there is a crack in your case as well.

 

[spoolints04]

Originally posted by 5150DSM
Please help...
I am running out of ideas and things keep getting worse. There is a lot of clunking coming from the tranny and/or axles. Half the time if I ease out the clutch in 1st it grabs fine and I am able to drive normally. All the other times I start to roll and then there is a either a clunk and/or a sensation of locking up in the front wheels. From there it's as I described above... Engine revs up but there is no acceleration in 1st, 2nd, and now 3rd. If it was the center dif, I would have the problem ALL of the time, right? I am still leaning towards slave fork and/or throwout bearing but I would like to have some better info before I start getting into dropping and pulling apart the tranny. Anything you guys can offer would be much appreciated. Thanks again for any and all help.
Tony

Look man, The clutch, clutch release fork or throwout bearing isn't going to make any clunking or grinding. So why is your heart set on it.
The reason you have no acceleration in 3rd now is because you've almost acomplished burning up your Viscous coupling. Keep on driving it, Don't worry soon I won't go anymore.

If you don't believe me then try this. Drain the tranny fuild. I'll bet it looks like Silver metalic paint. If the oil is clean, then I'll be damned.

 

[5150DSM]

Thanks for the input spoolints04... I don't have my heart set on anything just my fingers crossed as I am hoping to save this tranny. I tend to agree with you as far as symptomology; however, the fluid is clean, no metal, no burnt smell. Also the fact that I am sometimes(about half the time) able to ease off the line(to the point of nearly stalling) and get the 1st to engage properly, from which it then goes fine until the next stop has me confused. I will be dropping and opening the tranny tomorrow to visually inspect the gears, bearings, dif, VC, etc... However, I am just trying to gather as many experiences and insights or ideas that I can so I can prevent this in the future. Any help you guys can offer would be much appreciated. Thanks again for schooling me on the finer points of DSM trannies.
Tony

 

[spoolints04]

Oh ok, I just ready on another board that you changed the tranny fuild three weeks ago and it hasn't been driven much. That's why it's clean. Best of luck with it.