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gun18

Rs4 gearbox problem

Hi all, i have a problem.... This week i finally had the b5 fault free, i.e spent thousands and now the car is running like it should. Since i brought the b5 theres always been an issue with the gearbox which iv turned a blind eye to hoping it was ok. Today after putting some fuel in i drove off and decided to give it some boost so as im changing into second i hear a crunch and slowed down. As iv become aware that something has changed iv carried on driving, 3,4,5 and 6 engaged properly.. Try 1st and 2nd and it felt as though i was trying to lift a bowing 747 through 1000g of pressure (pardon the exaguration) very stiff and making a "gonk" kind of noise when it would go into them two gears.

I parked the car up hoping id come back And it would have cured itself but now it wont even engaged. It engages all the other gears fine. Can anyone help me with what iv broke and how much it will cost? Please note that the cars always had a wobbly knob when in gear in all the gears apart from 5. Its alsO had a brand new clutch, pressure plate and awe flywheel 300 miles ago.
tdiquattro

Sorry to tell you it's the usual 1st 2nd selector fault, gearbox rebuild I'm afraid.

This is a common fault on the 6 speed box, Audi introduced a number of revised parts on the late production boxes, including Teflon coated parts, but those boxes are very rare and only in the very last few cars made.

Most folks have the same early internals and it is just a matter of time before they fail...

The revised parts can be bought and installed once the box is removed and stripped down.

http://jhmotorsports.com/shop/cat...=66638e9b376ee68e75d675eacefee3dc

full kit..

http://jhmotorsports.com/shop/cat...=66638e9b376ee68e75d675eacefee3dc

Your symptoms are exactly the same as others have had, including me. For me it was also on a spirited change from 1st to 2nd that killed my box.
pjbRs

what year/ code did they fit the upgraded box?
sleeper_avant

i thaught it was just the very early ones that didnt get the revised gearboxes, i.e X and some Y plated cars?

purely internet forum hearsay and i couldnt gospel it
will1981

My 2001.5 S4 hitachi maf had 1st and 2nd gear syncro issues.

I never launched it......
tdiquattro

Here is an early post from 246, which shows the new boxes were only fitted to RS4s for the last 3 months of production.

(but some FTUs were replaced with FZWs under warranty)

RS4's built up to April 2001 had a gearbox designation code FDP. These had the well known potential faults with the 1st and 2nd gear synchros.

RS4's built from April 2001 had a gearbox with designation code FTU, which had modified carbon coated synchromesh rings for 1st and 2nd gears and modified locking collar/synchro-hub for 1st/2nd gear (same for the S4 gearbox also)

Any RS4's which have gearboxes replaced under warranty due to the above faults have the FZW designation service gearbox fitted, which again have the modified carbon coated synchromeshes fitted.
Aragorn

The weak synchros cause the grinding, and the grinding ruins the teeth on the synchro hub. The edges of the teeth get flattened off, which makes the hub stiff or jammed completely.

The replacement parts have a high friction coating on the synchros to help them work better, and additional hardening on the synchro hub to make it more difficult to wreck the teeth.

As Nigel says, gearbox rebuilt time now.

The parts are about 500quid from the dealer (iirc the rings are 75quid each and the synchro hub is about 300) then you need to remove and dismantle the box to install them.
sleeper_avant

Excelent info as usual on this forum!

Sean
coullstar

Is this the same issue as "the noisey first gear" problem or is that down tp pitting on the gear faces?
gun18

Sorry about the late reply, my email account has stopped notifing me with updates..    

Anyway once again i cannot thank you forum users enough for the help and advice!   I thought it would be an issue with synchros... After spending the best part of 6000 maintaing her i dont know if i should give up now or give it one more push.. Ahh well, cant beat an rs so i think its time to get borrowing again. Im also inclined in writing to audi about these "common fault" and asking for some compo, its not going to hurt and who knows, maybe they will give me the new b8 as a gesture of good will lol
calibra_se8

Pm Virdee on here, he does the rebuild kit at a great price.
MathiasS

My buddie has the latest 2001 S4 , it's an 08 I believe and his gearbox was FOOKED ass well so it's a myth the later models don't suffer from this
DJones

coullstar wrote:
Is this the same issue as "the noisey first gear" problem or is that down tp pitting on the gear faces?


No its a different issue and not actually that hard to fix, i do them myself now but when i first got a quote it was 250 + any parts found to be required.

Darren.

P.S. that's taking them the box not the car...
gun18

Iv sent virdee a message is he active on thr forums?
nomad

gun18 wrote:
Iv sent virdee a message is he active on thr forums?


Yes usually responds very fast!
Roberto Muggli

Alright, of course I HAD TO buy a car built in March 2001 and delivered on April 4th, 2001.

Given my usual luck I bet I have one of the last ones with the issue.

GRRRRrrrrr...
jpfour

Pm jimbo he may have a rebuilt rs4 box forsale meaning you could swap them then sell your current one on...
jpfour

Pm jimbo he may have a rebuilt rs4 box forsale meaning you could swap them then sell your current one on...
kmm

My rs is December 2001. The gearbox was takin into account when deciding on buying the car.
GrantF

DJones wrote:
coullstar wrote:
Is this the same issue as "the noisey first gear" problem or is that down tp pitting on the gear faces?


No its a different issue and not actually that hard to fix, i do them myself now but when i first got a quote it was 250 + any parts found to be required.

Darren.

P.S. that's taking them the box not the car...


What's the noisey 1st gear issue? Mines has done this since I bought it almost 6 years and 50k miles ago, but it's never got any worse and doesn't feel sticky 1st to 2nd gears. If it's an easy fix, I might consider it if\when I ever need a clutch doing.
coullstar

Same as mine then.  I was worried when I bought the car as I missed it during the test drive but the car had just been to MRC for a gearbox seal and I phoned to check.  Apparently its slight pitting of the gear face and was told if it didnt get anyworse over time then its nothing to really worry about.  
Its just a whining when in first.  Changes are all fine, same as yours.
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