Smooth shifting?

[Luzy V8]

OK, here is an update:

I did several investigations in the last 2 weeks.
I am impressed about the possible measurements you can do with VAG-COM. I recorded the data while driving, put them afterwards in Excel-files and created different graphs for visualization. I have shown them to a friend, who worked in doing transmission calibration for a couple of years.

1.) I measured the current from the TCM for the several valves inside the transmission valve body:
RESULT:
a) the time of activating and deactivating the valves is very short, which contributes to fast/sporty shifting, but is counterproductive for smooth shifting
b) there is no difference in the TCM signals between smooth and harsh shift situations
c) the torque converter clutch is mostly "open" while shifting. So my theory about a closed converter clutch while harsh shifting, could not be confirmed.
d) the ATF-pressure was inconspicuous, so no relation between harsh shifting and system pressure
e) how the TCM signals are physically "translated" in hydraulic behaviour of the valves, cannot be analyzed. This means that it is unclear when and how fast the valves are really moving

2.) I measured the fuel injection quantity while driving/shifting:
RESULT:
a) the injection quantity are slightly reduced before/while shifting, and that's in general how it should be. But to realize smoother shifting, the quantities should be reduced further, which on the other hand is counterproductive for fast vehicle acceleration
b) no relation between injection quantity changes and harsh shifting situations

3.) I contacted an Engineer of VWoA to get confirmation about having the latest Software for ECM and TCM in my vehicle (2004, V:
RESULT:
a) he confirmed that "P0000, A4.2.4" is the latest version for the ECM
b) he confirmed that "P0210" is the latest version for the TCM

4.) I performed several TCM reset:
RESULT:
a) for 2-3 days the shifting behaviour is acceptable, but afterwards it is becoming worse. This means that the TCM is "learning" wrong.
b) 4200 code is smoother than 4153, but not the satisfying solution long term (for me)

5.) I tried to recode my ECM to 11xxx (Europe EU4), because in Europe this shifting issue is not occuring that much and I thought it could depend on the combination of the ECM and TCM software :
RESULT:
a) was not possible. ECM rejected this code.

6.) the torque converting between engine and transmission is relatively firm. This means, at engine idle, when releasing the brakes, the vehicle is relatively quick to start moving forward. This is counterproductive for smooth shifting. On some cars with softer torque converting, you can release the brakes and the car does still remain (more or less) at the same position. This is also an effect of the utilized ATF viscosity. A softer torque converting worsens the fuel economy….. and that's something we are absolutely not interested in.

So what is the overall result of all that ?
- the TCM hardware is OK
- I strongly believe that the combination of the (improvable) transmission calibration and the known "Unfavourable tolerances in the hydraulics of the automatic gearbox" (including valve body) is causing the harsh shifting at low load/speed.
- this transmission type seems to react very sensitive to hydraulic tolerances. That's the reason why some people are complaining more, and the other less.

Unfortunately I guess the final solution to fix it, is (at least) a new valve body, if not an entire transmission. This is also the experience out from the threads in the Touareg forums.

So somehow I hope it becomes worse (as with my first transmission), in order to utilize this (extented) warranty I still have for my beauty.

Cheers.

[Mighty T]

The transmission is being replaced on my wife's 04 v8 as we speak. It began clunking as we would start to accelerate up a hill or after coasting a bit. It felt as though it was attempting to downshift as we were giving it more gas to maintain speed or accelerate. The problem was not related to any specific gear. It would happen at 70 mph as we headed up a hill on the highway or if we were going up the street in our neighborhood.
The vehicle seemed to convulse three or four times and then run properly.
This vehicle has not been used to tow regularly and when it was, it was a small 6x12 utility trailer. The sport and manual shifting was only used on very few occasions. The mileage is 64k, which seems to me to be what should be the half life of the tranny on a vehicle that's used for such light duty.
The cost of such a repair out of warranty? Lets try the $9K range.
This is the only vehicle that I've ever purchased an extended warranty for. I'm going to be out a cool $100.00.
I'll post an update as to how things get put back together since the engine must be pulled to accommodate the replacement.

[joeames]

Originally Posted by Mighty T

The transmission is being replaced on my wife's 04 v8 as we speak. It began clunking ...

The cost of such a repair out of warranty? Lets try the $9K range.
This is the only vehicle that I've ever purchased an extended warranty for. I'm going to be out a cool $100.00.

I'll post an update as to how things get put back together since the engine must be pulled to accommodate the replacement.

I had this exact work done summer 2006. The shift program seemed to conflict with the stepper motor software, shredding the innards of both to tiny bits after a short while. Of course, it also over stressed the drive shaft and read axle, so you may want to pay particular attention to those components.

In my case, these parts were replaced (under warranty, thank God! although that did not help me with the weeks of lost time involved in 23 separate trips to the dealership... threat of a lawsuit did that )

1. Valve body
2. Transmission
3. Stepper motor
4. Prop shaft
5. Prop shaft carrier(s?)
6. Rear differential
7. Transmission coolant hose (rubbed through resulting in catastrophic fluid loss; never determined what caused that one)
8. Transmission cooler

[Mighty T]

VW kept this car for 3 weeks. Offered a replacement but I was going to be on vacation for most of the time so I let them off the hook.
While the engine was out I had the timing belt, tensioner and guides replaced. 64k miles is early but better than paying for the labor later. The work cost me around $1250.00 including the $100.00 deductible.
The car seems to be runnung great. The original trans. always shifted hard compared to this new one. It felt like the TH400 that I had as a teenager after the shift kit was installed. I just thought it shifted hard. Didn't seem excessive.
Repairs went well car seems great.
Get your extended warranty!!

[joeames]

Originally Posted by Mighty T

<snip>
Get your extended warranty!!

Absolutely! I just bought my Treg off lease and now am in the market for an additional extended VW warranty. The good news is this: I have not had a single issue with my 04 since the trans problems were corrected, and that was ~40,000 miles ago or a little more.

Knock on wood this thing will give me another 100,000mi of good trouble-free service!