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Discussion Starter #1
Hi all, I have a 2001 2.5 TDI Caravelle with an automatic gearbox, and it has an issue! Since I got it just over a year ago I've changed the ATF a couple of times - once because I had just bought it and so did a service, and then again when it developed a leak around the gasket because I tightened the sump nuts too much. I bought a torque wrench small enough, and another new gasket and filter, and also a filler pipe, seal and cap and put it all back together properly with the correct torque setting on the bolts.

I've got VCDS so went through the correct procedure to fill it up - temp to around 35 degrees, then top up until there is just a trickle coming out of the drain plug - but now it seems to be blowing ATF out of the filler cap. Is there something in the box that might be building up pressure or is it possible that the breather could be blocked? It doesn't blow it out on idle but I took it for a run last week (around 50 miles) after I'd changed the filter and put the new filler tube on, and that's when it sprayed it out. The changes seem ok and there's no weird noises (that I can hear above the noise of the engine) but it's doing my head it and I'm determined not to switch it to a manual!
 

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Temp at 35, engine running in P?
The torque converter acts as a pump, so engine has to be running when doing the level check.
 

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Discussion Starter #3
Temp at 35, engine running in P?
The torque converter acts as a pump, so engine has to be running when doing the level check.
Hi, yes, engine running and gearbox in P, and I went up and down the gears a few times whilst it was getting up to temperature. It's on pretty level ground too, but i might have another look at the temp and topping up again in case I somehow over filled it.
 

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Hi, yes, engine running and gearbox in P, and I went up and down the gears a few times whilst it was getting up to temperature. It's on pretty level ground too, but i might have another look at the temp and topping up again in case I somehow over filled it.
Did you change the complete filler tube with new cap + oil seal?
VW mechanics I've spoken to seem to overfill deliberately, get up to temp then undo the sump bolt & allow it to find it's own level. This way they dilute the remaining degraded old oil a little more.
 

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Discussion Starter #5
Yes, brand new tube, cap and seals - I was speaking to Brickwerks to see if they could get me one a few weeks ago and they've now added them to their site. Over the last year I've probably put around 10 litres of new oil! First batch for the original oil change I did, then another batch for a second change I did earlier this year because the sump gasket started leaking from where I hadn't torqued the bolts up correctly. Then I bought a small torque wrench, and a new gasket and filter set, put it all on correctly, but it was leaking again, this time from a stripped thread in the sump, so I helicoiled it around 6 weeks ago. Then it started leaking from the filler tube, so a couple of weeks ago I got the new filler and seals from Brickwerks, dropped the sump and installed them and then did the VCDS thing but it's still blowing out.

I didn't change the gasket or filter this time though, as I figured it's the 3rd new one in the last year, but I've just remembered the foam filter stuff inside it seemed to have moved - when I looked thought the big hole I could see a folded edge rather than it just being flat, so maybe that's caused a bit of a pressure build up? Anyway, I've ordered a new filter so I'll give that a whirl when it gets her, along with a new cooler/heat exchanger, just in case it's started to pressurise the box with a water leak. The oil when it comes out is a very light brown/pinky colour, so I'll see what it's like when I drop it again when the bits arrive. I did slightly over fill it, but with the sump plug off, whilst it was getting up to temp, to make sure it wasn't just a few drips from the filter going straight out.
 

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Fluid should be "pee yellow" if it's the correct stuff!
Damned expensive, but the only stuff that allows these boxes to last is the VW spec.
It is NOT std ATF....but a fully synthetic fluid.

Briskwerks (NOT their fault, they did '"phone a specialist" before changing mine) some years ago for std ATF.
On the way home from UK to Norway, it dropped out of lockup and at 160kph in Germany, red-lined the engine...and in the end cost me a new gearbox (4 grand including fitting!!!).
That was a distance of about 1500km before it totally wrecked it. :eek:
 

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Discussion Starter #7
I've been buying what is supposed to be the proper stuff from a local VW place - G052 or whatever it is - and it seems to be pink? I thought the power steering fluid was supposed to be yellow? I recently got some of the synthetic stuff from Brickwerks though because the VW dealership is closed, Fuchs Titan ATF 5005 which I did check for compatibility on the Fuchs website.

When I put the new filter in though, I'll check the seal on the new filler pipe is on correctly, just in case I somehow cocked it up.

I did have a Sierra 4X4 estate gearbox lock up on me about 20 years ago - doing 80mph when it went bang and locked up in 1st gear, so all 4 wheels left a bit of rubber on the road until I dipped the clutch, which wasn't scary at all! Then I had a 10 mile drive home in 1st gear on the side roads, as the clutch still worked, and when I took that gearbox off, it was full of rusty water, no oil :eek:
 

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You can use Valvoline Maxlife which has the VW spec also Febi do one too. Both are expensive but not as bad as the VW brand. The rumours I've heard is that Febi had a hand in the VW original but can't guarantee the truth in this.
If you go to TPS they supply Fuch's titan for the power steering fluid. The VW gearbox fluid is yellow & goes a reddish/brown when cooked.
If you had a kink in the seal then the fluid pump would suck oil through that before the filter effectively making about 1ltr of fluid redundant which could give you issues.
 

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Discussion Starter #9
Thanks for all the replies so far, I'm going to give the new filter a try when it gets here today or tomorrow. I'm sure though that the VW G052 stuff i got was red/pink and not yellow and that was from a VW main dealer - MON Motors in Chippenham - and was about £18 a litre. Is there a specific code I should look for to get the correct oil? The last stuff I bought was a couple of weeks ago from Brickwerks, Fuchs Titan ATF 5005 and I'm sure that was red too.
 
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