97 B5/A4 2.8L AFC Quattro 5sp man

This all started about 2 months ago when I was suddenly unable to shift into 5th, it felt as if it was locked out. So i assumed, because there were no other symptoms, it was the linkage since it had given me issues in the past (the adjustment bolt had loosened and caused random loss of 1st, 3rd & 5th).

After 2 weeks of planning on checking it out I finally realized it probably wasn't the linkage when my speedo went dead.

About a week later I had a few minutes and decided to pull out my VSS, and it looked like it had been mashed and cut open by something. This is when I decided I was going to be opening up my transmission.

Cut to over a month later and here I am finally doing it, figured I would document my progress so if i do have any questions there will be some background in place.

As of tonight I have removed the trans and found other issues along the way.
I'll update in the morning.

 

So I noticed the transmission code was odd.

The date code indicates the trans was built in October of 1998, which means it's not the original trans.
Looks like this isn't it's first trans issue.

 

Interesting. I've heard plenty of stories of issues in the trans that should have come in your car originally, but none built later than about 97. What are your plans now? Rebuild? Replace? 6spd swap?

 

For cost reasons I was planning on just rebuilding but at this point I'm not sure it would be that much cheaper.

 

So I got a bunch done yesterday.
Pulled the Torsen and the trans cover and found some surprises.


so it looked like one of my gears ate it, but after looking at them i found no damage.
Looking into the VSS hole.

This would explain the VSS failure.

 

After pulling off the diff cover i found more gifts.

speedo drive in three pieces.

Some more teeth.

 

Looks like somebody threw a hand grenade in there o_O

 

So the pilot gear is stripped pretty good.



There are some gouges on the inside of the diff housing.


I'm having trouble finding hard parts for the 01a, anyone know the best place to get a pilot gear/shaft and ring gear? Should i just find a used trans?

 

Prolly would be best to try to find a used one. Rebuild kits are hard to come by and cost prohibitive from what I've been able to find, plus they don't include actual gears. Just seals an synchros and such:

JH Motorsports Inc. ($600)

Advanced Automotion ($1100)

 

So I just got off the phone with my local audi parts guy and he checked the trans code and found that the DWM was made for the facelift models and the ring and pinion set are available for $1000 so not getting those.

I think i'm going to just look for a used trans or one with a blown 3rd since i've heard thats common with these and rebuild it with part from mine.