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leaking electrical connector on transmission

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frankvan

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Discussion starter · #1 ·
Driving my touareg it got stuck in D3 - wouldn't shift out of 3rd gear.
Cycling between P/R/N/D got it working again. Drove straight home.
Looking at the transmission there's three electrical connections - one them is external with the harness going forward to the front right wheel output shaft (i think)
But one of the two connections going into the tranny was wet with red fluid - assume that's the ATF vw uses. Cleaned it all up, re-assembled and quick road test showed no issues.
Looks like someone might have been here before because two of the wires look like they've been spliced
Can't find any diagrams or such describing it.
Does anyone know of a part number for this connector on the transmission (the receiving connection that's mounted actually in the tranny body), and is it replaceable (what does it connect to inside the transmission?)
 
#3 ·
Just my opinion, which may be worth nothing, but I would see about getting a replacement connector and properly splicing into the existing wiring harness. By properly I mean cutting back the wires and soldering on new ones that are covered in heatshrink tubing that are then covered by a larger heatshrink tubing.

Also...find out where that fluid is coming from and fix it so it doesn't do any damage again.


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#4 ·
frankvan said:
Driving my touareg it got stuck in D3 - wouldn't shift out of 3rd gear.
Click to expand...
That's the emergency mode. The transmission goes into that whenever it detects a major problem with the controller.

frankvan said:
But one of the two connections going into the tranny was wet with red fluid - assume that's the ATF vw uses.
Click to expand...
The question is: where did that come from? Did it just leak over the connector, or did it leak through the connector. If the latter, you've a major problem at hand.

frankvan said:
Does anyone know of a part number for this connector on the transmission (the receiving connection that's mounted actually in the tranny body)
Click to expand...
The connector is not sold separately, only as part of an internal wiring harness. Part number should be "09D 927 363 G". Cost is $200 when ordered from VW, $50 for an "aftermarket" one.

frankvan said:
and is it replaceable (what does it connect to inside the transmission?)
Click to expand...
It's used to control the solenoid valves on the valve body. Ie. this is what's actually shifts between gears.
 
#5 ·
As above there is a harness inside the gearbox that sits in the ATF and has been known to leak and cause problems.

Some yyears ago someone on here did a successful DIY with photos whilst lying on his back on his garage floor to remove and replace the harness!

I recall he used a small blue plastic tool to carefully and correctly disconnect the connections.

Maybe someone can find that DIY?
 
Discussion starter · #6 ·
the other two connectors and surrounding transmission body are bone dry so i suspect it is leaky connector. Looks like it is leaking from the inside part of the connector as it's dry where the connector goes into the transmission (so not as simple as replacing an o-ring or gooping it up with gasket sealant.)
 
#8 ·
frankvan said:
https://volkswagen.7zap.com/en/rdw/touareg/toua/2006-478/9/927-927070/
maybe an 0-ring is available separate (item 12 in the diagram in th link)?
Click to expand...
I thought your problem was the bigger, 14-pin connector. If so, then the o-ring for that would be part 14 (not 12) in the diagram. The connector you've marked with red is the smaller connector, which has that pink securing bracket showing in your photo.

Either way, the o-ring is only there for stopping the oil leaking _past_ (around) the connector, not _through_ it. If the oil is seeping actually past or through the pin(hole)s in the connector and not the whole connector housing, then replacing that o-ring will be no help to you.

You'd need to replace it regardless though if you're going to replace the connector, because the old one has now lost its elasticity and most likely won't seal properly anymore if you replace the connector with the solenoid harness. But I don't think you'd need to buy it separately, because the new harness should also come with a new o-ring.
 
Discussion starter · #9 ·
ya i was thinking about that afterwards, it's leaking inside the connector so just replacing the o-ring wouldn't help
(part 12 and 14 are the same part number, but you are correct that 14 goes to the connector in question!) Would assume that the o-ring comes with the wiring harness anyways as it could be a pain to slide it past all those connectors - and you'll still have to open the transmission to disconnect all those internal connections...
 
#10 ·
Hi,
I have the same issue of oil seeping out of the Transmission connector.

I have done a pretty extensive search of the forums and can't find the DIY fix that Nooby refers to.

Anybody out there know where it is?
 
#11 ·
gregs said:
Hi,
I have the same issue of oil seeping out of the Transmission connector.

I have done a pretty extensive search of the forums and can't find the DIY fix that Nooby refers to.

Anybody out there know where it is?
Click to expand...
I don't know where it is (or if it exists, because I can't recall having come across it), but to me it seems like this job would be like a regular transmission fluid change (including filter replacement), with the only difference being having to unbolt the connector from the transmission housing and replacing it with the new one before putting the new oil filter/thinner in and proceeding as normal during a regular change procedure.

That procedure is documented here:
https://www.clubtouareg.com/forums/f95/diy-transmission-fluid-change-pics-atf-82168.html
and you can actually see the harness you've to replace in this picture (the green clips are the solenoid valve connectors of the harness):
https://www.clubtouareg.com/forums/attachment.php?attachmentid=19678&d=1357404937
 
#12 ·
#13 ·
I recently noticed that the harnass connection on the right (passenger) side is wicking fluid up the wiring loom. Does anyone know if there is a rubber seal there that can be replaced and if so what is the part number? I've searched O9D parts and can not find anything. I forgot to take a pic but if needed I can lift the truck again, remove the plastic cover and take a photo.
 
#16 · (Edited)
I recently got under the Treg again and snapped pics. The bottom connector is the leaky one. I called the dealer and he told me that both connectors use the same o-ring and they are available. It's probably seeking through the connector and not the O-ring? Parts 446 and 447:
Image
Image
Image
 
#18 ·
You only replace the valve chest if you have THE THUMP.

The valve bores can wear and at around 38-40 mph as you are are tootling along and meet a slight rise in the road the box will change from 5th to 4th with THE THUMP which will make you think you just left the gearbox on the road behind you!

What's actually happened is the downward gear change has been delayed by the valve sticking in the worn bores.

If you don't have THE THUMP - and trust me you will know if you have it - you don't need to replace the valve chest.

You can't buy new chests now unless you are lucky finding old stock somewhere, so you get a refurbished chest instead from the likes of RevMax.
 
#19 ·
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