Mk3 1995 automatic gearbox problems?

[spacem_uk]

Hi

My first post here! :-D

We have a N Reg 1995 Volkswagen Golf CL 1.8 automatic (4 speed), with engine code ACC). No warning lights are on the dash board. 84k mileage.

Have only had it a short time and it has always been a bit 'revvy' changing up from 3rd to 4th when in Drive, seeming to change up through 1,2, (slight rev here) 3 and then the RPMs drop slightly as if its going to neutral, to change up to 4th, but it then revs very high and feels like it is slipping, the harder you press the accelerator the more revs you get but not really go any faster, if you ease off the accelerator on the flat it will generally get up into 4th.

It really doesn't like going up hills or inclines of any kind, dropping almost immediately out of 4th but not making into 3rd fully, revving 3,500RPMs-6000RPMs as if slipping. Eventually if you go slow enough uphill it does seem to drop fully out of revving/slipping and "lock" into 3rd (or lower?) and will quite happily climb up the hills without the slipping. Once over the summit of a hill it will change up into 4th on the way downhill.

However we just had the gearbox gasket and filter changed and new ATF fluid put in (3 litres, added until it dripped out the bottom), since the change it is now very reluctant to go into 4th at all, revving very high after getting to 3rd, almost upto the redline where it hits the limiter and you can still only be getting 30mph.

Was driving it home on the motorway after the fluid change, was doing 60, pulled out to go round a lorry and put me foot down to overtake, the REVs went almost to the redline and I went SLOWER, dropping to 40mph! :-o Had to pull back in behind the lorry and try and coax it back into 4th, it never got there as was on a slight incline. Ended up on the hard shoulder to recover, then limped along the hardshoulder to the next down hill stint and a big enough gap in the traffic to get out again and made it home. Nightmare.

Today drove it in the 3 setting, rather than Drive and it seems to accelerate much better, never entering the "slipping" mode it hits between 3rd and 4th. However we are a bit limited to the speed we can do as we only have gears 1,2 and 3 in use. On the flat or downhill you can, once doing about 40-50mph in the 3 setting move the gear select into Drive and it changes up into 4th without much problem.

Could this be a gearbox management problem? Mechanically it seems ok when using the 3 setting to get upto 40-50mph and then shifting into Drive to go into 4th.

Its just like the gearbox doesn't seem to 'know' to hold onto 3rd till 40-50mph and then change up to 4th.

Have tried the "TCU reset" via the ignition but this didn't seem to do anything, perhaps it is too old, being a 95 model.

Looking for a automatic gearbox/VW specialist near Birmingham Tamworth to take a look.

[kabovill]

I have an exact problem. Did you get a solution?

[spacem_uk]

Had the box rebuilt as the "K3" clutch pack was worn. The abrasive material in the clutch was just worn out so it couldn't lock into 3rd or 4th properly.

However I think from my motorway stint in it it got so hot it cooked the shaft inside, actually warped the end of it.

4 hours to rip it all apart and find the parts that needed replacing, 4 hours to rebuild it, bench test it and refit to the car.

Picked it up and it accelerated, up hills it was a dream. Ken said the only other thing he could do to make it even better was one of the (four?) solenoid barrels was a bit worn, so although the box re-build was fine there was a slight hesitation at the 3rd/4th change.

2 weeks later and although alot better than it originally was, it didn't feel quite right having the hesitation (the worn solenoid was probably having to work twice as hard to do its job due to it being worn)

Worn solenoid was replaced. Ken did a grand job and it drives like a new car now. Very happy and it came in under the cost of a reconditioned box by a few hundred quid, plus we know exactly what was replaced.

Transmission Technology UK located in Knowle, near Solihull. You can find the contact details on yell.co.uk

Best Regards
Neil

[kabovill]

Hi again Spacem. See, I should have given more details.

I actually changed my gear-box as the first one would engage gear 1 only. The Revs would go high & maximum speed would be 40km/hr though I could do more than 40km/hr but still at gear 1.

Now I changed it (with a second hand that was actually running) & still the same thing happens. (I will make a print-out & forward this to my machanic)

If you might know any possible defects please respond.

I must appreciate that was a quick response.


Regards
Kabo

[spacem_uk]

Hi

Gear selection problems could be the switch sending your gear selection from the gear stick to the electronics in the gearbox (Transmission Control Unit?).

We had a fault code that was something like "TCU gear select out of parameters/range" when connected to diagnostic machine. However, when they swapped the switch out for a new one and the car still had the same problems, so proceeded with the rebuild.

I really didn't want to chance a second hand (could be just as bad, or worse...) or reconditioned unit (3 to 6 months guarantee?!! for 1500+) given the amount of labour involved.

There are an amazing amount of parts inside, I saw all of them out on the bench when it was taken apart. So complicated.

Best Regards
Neil

[kabovill]

Thanx again.

I will let you know if I am successful. Guess my solution would be of help to others, that is if I manage.

Regards
Kabo