Rebuilding the transmission on an Audi S8, particularly the high-performance models like the D2 (1996-2003) or D3 (2006-2010), is a complex task that requires a good understanding of automotive mechanics, specialized tools, and a well-organized workspace. click here for more details on the download manual…..
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Below is an overview of the components involved in the transmission rebuild process, along with detailed descriptions of each step.
### Components of the Transmission
1. **Transmission Case**: The outer shell that houses all internal components of the transmission. It provides structural integrity and protection.
2. **Torque Converter**: This component connects the engine to the transmission and converts engine power into hydraulic pressure. It allows the vehicle to idle without stalling.
3. **Transmission Fluid Pump**: This pump circulates transmission fluid under pressure to operate hydraulic components and lubricate moving parts.
4. **Valve Body**: A complex assembly of channels and valves that directs transmission fluid to various components, controlling gear selection and shifting.
5. **Clutch Packs**: These friction plates engage and disengage to facilitate gear changes. They are critical for smooth operation and power transfer.
6. **Planetary Gear Sets**: These provide the different gear ratios necessary for acceleration and speed. They consist of a sun gear, planet gears, and a ring gear.
7. **Input Shaft and Output Shaft**: The input shaft connects to the engine while the output shaft connects to the drive wheels, transferring power.
8. **Mechatronic Unit (for D3 models)**: This unit combines mechanical and electronic components, controlling the transmission electronically for smoother shifting.
9. **Seals and Gaskets**: These ensure no fluid leaks from the transmission, providing a tight seal between components.
10. **Transmission Fluid**: Vital for lubrication, cooling, and hydraulic pressure; the type of fluid used is critical for performance.
### Tools Needed
– Socket set (metric)
– Wrench set (metric)
– Torque wrench
– Screwdriver set
– Pliers and cutting tools
– Transmission jack
– Fluid pump
– Clean workspace with ample lighting
– Transmission rebuild kit (including seals, gaskets, and clutch plates)
– Service manual for specific torque specifications and procedures
### Step-by-Step Transmission Rebuild Process
#### 1. Preparation
– **Workspace Setup**: Ensure you have a clean, well-lit area with plenty of space for the transmission components.
– **Gather Tools and Parts**: Collect all necessary tools and the rebuild kit.
#### 2. Removal of the Transmission
– **Disconnect Battery**: Always disconnect the battery to prevent electrical issues.
– **Raise the Vehicle**: Use a hydraulic jack to lift the vehicle and secure it on jack stands.
– **Drain Transmission Fluid**: Remove the transmission pan and drain the fluid into a suitable container.
– **Disconnect Torque Converter**: Remove the bolts that connect the torque converter to the flex plate.
– **Remove Transmission Mounts**: Disconnect the transmission from the engine and any supporting mounts or brackets.
– **Pull the Transmission**: Carefully slide the transmission out of the vehicle using a transmission jack.
#### 3. disassembly of the Transmission
– **Remove the Bell Housing**: Unbolt and remove the bell housing to access internal components.
– **Take Out the Torque Converter**: Carefully pull the torque converter off the input shaft.
– **Separate the Transmission Case**: Unbolt and separate the upper and lower halves of the transmission case.
– **Remove the Valve Body**: Detach the valve body, taking Note of how components fit together for reassembly.
– **Take Out Clutch Packs**: Remove the clutch packs and any associated springs or retainers.
– **Take Apart Planetary Gear Sets**: Remove the planetary gears, noting their orientation for reassembly.
– **Inspect Components**: Check for wear
and damage on all internal components, including gears, bearings, and seals.
#### 4. Cleaning and Inspection
– **Clean All Parts**: Use solvent and brushes to clean all components thoroughly. Pay special attention to the valve body and channels.
– **Inspect for Damage**: Check all parts for wear, cracks, or other damage. Replace any components that are not in good condition.
#### 5. Reassembly
– **Install New Seals and Gaskets**: Ensure that all seals and gaskets from the rebuild kit are installed correctly.
– **Reassemble Planetary Gear Sets**: Reinstall the planetary gears in the correct orientation.
– **Install Clutch Packs**: Reinsert the clutch packs, ensuring they are seated properly.
– **Install Valve Body**: Carefully reinstall the valve body, ensuring all passages are clear.
– **Reattach Torque Converter**: Slide the torque converter back onto the input shaft and secure it to the flex plate.
– **Reassemble Transmission Case**: Align and bolt the upper and lower halves of the transmission case together.
#### 6. Installation of the Transmission
– **Lift the Transmission into Place**: Use the transmission jack to position the transmission back into the vehicle.
– **Reattach Transmission Mounts**: Secure the transmission to the engine and any mounts.
– **Reconnect Torque Converter**: Ensure the torque converter is properly bolted to the flex plate.
– **Reconnect Fluid Lines and Harnesses**: Attach any electrical connectors, fluid lines, and linkage.
#### 7. Final Steps
– **Fill with Transmission Fluid**: Use the proper type of transmission fluid and fill it to the correct level.
– **Reconnect Battery**: Reattach the battery terminals.
– **Test Drive**: Start the engine and allow it to idle. Check for leaks and perform a test drive to ensure proper operation.
### Conclusion
Rebuilding a transmission in an Audi S8 is not a task for the faint-hearted and requires careful attention to detail, mechanical skills, and knowledge of the specific transmission system. If you’re not experienced, it may be beneficial to consult a professional mechanic. Always refer to the specific service manual for your Audi S8 model for detailed specifications and torque settings.
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