Automatic Gearbox Repairs and Reconditioning

Common General Faults

• Clutch slippage or burnout

• Torque Converter slippage or burnout

• Torque Converter/Oil pump leakage

• Pressure Loss

• Harsh shifts (Banging into gear)

• Limp mode or Safe mode

• Warning lights present

• Not shifting gears

• Bumping into drive or reverse

• Does not engage drive or reverse

• Slippage or harsh shifts when hot

• Non engagement, slippage or harsh shifts when cold

• Gearbox oil leaks

• Whining noise from gearbox

• Grinding noise in gearbox

• Incorrect fluid in gearbox (most commonly seen with CVT and DSG/DCT gearboxes)

Common Faults by make:

• Valve body Faults:

  1. Volvo 5 speed automatic (55-50/1SN) valve body fault – The common symptom being harsh shifts when the vehicle warms up after approximately 15 minutes of driving

  2. Volvo 6 speed automatic (TF80/1SN) valve body fault – The common symptom being harsh shifts when the vehicle warms up after approximately 15 minutes of driving

  3. Renault/Citroen/Peugeot 6 speed automatic (TF80/1SN) valve body fault – The common symptom being harsh shifts when the vehicle warms up after approximately 15 minutes of driving

  4. VW Golf Polo 6 speed automatic (09G) valve body fault – The common symptom being harsh shifts when the vehicle warms up after approximately 15 minutes of driving

• Gearbox mechanical faults:

  1. BMW E46 5 speed automatic (5HP19) Oil pump failure

  2. BMW E90/1 & Jaguar 6 speed (6HP19/21/26/28) Internal pressure loss – slippage occurring on heavy acceleration

  3. Ford Ranger/Mazda BT50 5 speed automatic (5R55S/W) – complete gearbox failure/burnout – Full overhaul required including solenoid block

  4. Ford Ranger/Mazda BT50 – complete gearbox failure/burnout – Full overhaul required including solenoid block

  5. Ford Ranger/Mazda BT50 6 speed automatic (6R80) – complete gearbox failure/burnout – Full overhaul required including mechatronics

  6. VW/Audi 7 speed DSG – Clutch failure

• Electroplate, conductor plate and transmission control unit (TCM) faults:

  1. Mercedes benz, 5 Speed rear wheel drive electroplate replacement (No coding required)

  2. Mercedes benz, 7 Speed rear wheel drive electroplate replacement, electroplate requires coding after fitment

  3. Mercedes benz, W169 cvt electroplate replacement, electroplate requires coding after fitment

  4. Audi B6 and B7 transmission control module (TCM) Repair – Common diagnostic fault code “Transmission range sensor”

• Common mechatronics failures:

  1. BMW 6 speed ZF mechatronics or solenoid failure – new unit required

  2. Audi/VW 6 speed DSG (02E) mechatronics failure – new unit required

  3. Audi/VW 7 speed front wheel drive DSG (0AM) mechatronics failure – new unit required

  4. Audi Q5 7 speed 4WD DSG (0B5) mechatronics failure – new unit required