[zorak]

Hi everyone, I'm the owner of a 2005 Passat TDI. Like the title says, I didn't expect to work on my car but it looks like my car has decided to grant me my childhood wish: to work on cars. I've only done a couple minor repairs but want to be able to do nearly every repair. I would love to be comfortable enough to find one of these in non-working condition and bring it back to life.

 

[chittychittybangbang]

Torque converter? What made you decide to replace that?

FYI, use a quality CV joint, not a cheap replacement part because they can cause vibration at idle when stopped. See the CV joint and boot replacement article for a video.

 

[zorak]

TC - Check engine light came on so i took it by my (former) local shop. Mechanic said the code was for a bad TC. He also said the transmission fluid looked very dirty, that it was a sign of bad seals in the TC. From everything I've seen this repair is way out of my league, but I do have the advantage of not being in a rush to fix it. I work from home so my car mostly just sits in the garage.

I will steer clear of cheap parts! Thanks for the info.

 

[NJ2dc]

Isn't that how everyone becomes an accidental mechanic? Since you work at home, why not at least try the transmission repair? "I've only done a couple minor repairs but want to be able to do nearly every repair."

 

[zorak]

Isn't that how everyone becomes an accidental mechanic? Since you work at home, why not at least try the transmission repair? "I've only done a couple minor repairs but want to be able to do nearly every repair."

Now that is what I like to hear - why not do it myself? I need to learn what needs to happen in the repair. I thought this repair would be one that is difficult/impossible for the solo home mechanic. But I don't really know.

 

[chittychittybangbang]

It's more difficult but here is the basic summary:
disconnect axles
Disconnect exhaust pipe
disconnect starter
remove 3 electrical connections
disconnect shifter cable
loosen 3 torx torque converter bolts
support engine and loosen bellhousing bolts
remove transmission.

There are writeups for almost every step:

http://www.myturbodiesel.com/1000q/b5/CV-boot-broken-replacement.htm
http://www.myturbodiesel.com/1000q/b5/engine-removal-passat.htm
http://www.myturbodiesel.com/1000q/b5/engine-removal-passat.htm

The last one shows both engine and transmission removal - omit the steps for engine removal.

 

[zorak]

Broken down like that it doesn't sound too bad. I could take a week or two and do a few steps a night. Aside from the tools listed in the instructional links, what is needed to make a repair like that go smoothly? Where can I source the parts online?

BTW this morning I discovered that the oil dipstick tube gets very brittle. I barely nudged it and it cracked. Luckily I didn't lose any pieces into the engine.

 

[chittychittybangbang]

A helper. Just take your time and take a step back think about what you're doing if you get stuck or frustrated.

Sources for an engine support are northern tools or harbor freight. A transmission jack can be purchased from harbor freight for pretty cheap. Get a good set of tools - sears craftsman are fine. You must get a good torque wrench. You'll need a set of torx drivers, 3/8" socket is fine.

And of course, a good shop will have a lift and transmission jack on hand so it should be faster for them, especially since they should have experience removing transmissions. The only thing to watch out for is the torque converter installation and making sure everything is torqued down.

 

[zorak]

Can I rent the engine hoist/lift or is that not needed (tranny drops out from bottom?).

Is there a particular part # to search for the TC? Are they available as rebuilt units or only oem?

 

[chittychittybangbang]

The tranny drops out the bottom but you should support the engine somehow because it rests on 5 spots. 1 on the front, 2 on the sides, and 2 on the transmission. I don't know where you can rent a cherry picker. I bought a used one and if I sell it, it should go for about the same price so using it was effectively free.

Don't know about rebuilt TC, sorry. The part number for the VW Passat TDI torque converter is VW# 01v 323 572 b (01v323572b) code number q61. The transmission type is 01v, model GMR, made by ZF.