Audi A2 1.2. TDI 2002 Gearbox hydraulics problems

Hei EnnToTre. Jeg har hatt lignende prob…. Sorry…
I have had a similar problem with my 1.2. The car disables itself if the hydraulics is not up to the job of controlling the clutch and gearbox. Mine obviously has a leakage past the one-way valve in the pump/accumulator module. Then the pump is not capable of maintaining adequate pressure in situations with meny gear/clutch operations.
I have not yet repaired the valve. It is a "simple" O-ring and X-ring renewal job. Adding some RVS to the oil has helped me through the winter but is has to be fixed this summer.
 
Tore Kjernmoen said:
Hei EnnToTre. Jeg har hatt lignende prob…. Sorry…
I have had a similar problem with my 1.2. The car disables itself if the hydraulics is not up to the job of controlling the clutch and gearbox. Mine obviously has a leakage past the one-way valve in the pump/accumulator module. Then the pump is not capable of maintaining adequate pressure in situations with meny gear/clutch operations.
I have not yet repaired the valve. It is a "simple" O-ring and X-ring renewal job. Adding some RVS to the oil has helped me through the winter but is has to be fixed this summer.
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Are you sure that the problem is a non-return valve and not the accumulator?

RAB
 
Can't be sure until repair is done. Accumulator is new. Oil level is very low. If I fill up the oil is purged overnight through the vent in the reservoir cap. I think this point to the oil is pushed from the accumulator back to the reservoir. In the morning the reservoir is full but as soon as the pump stops the level is very low.
 
If you have oil coming out of the green cap, the system has been over-filled. To check the correct level, disconnect the hydraulic unit electrically and loosen the accumulator half a turn. The true level will now be shown in the reservoir. Top up if necessary - level should be within the rectangle. Retighten the accumulator and reconnect the hydraulic unit. We have three of these units and they never keep full pressure overnight - it's normal. A low level after the pump has stopped means a good accumulator.

RAB
 
Level after 10 hours standstill is 1cm below the rectangle.
Level after the pump has stopped is 4 cm below the rectangle.
I know owners is not supposed to open the bonnet and check this themselves. I had expect that the level should be checked in normal use, not having to disconnect the connector and loosen the accumulator. Will use your method and top up if necessary. Thanks.
 
Tore Kjernmoen said:
I know owners is not supposed to open the bonnet and check this themselves.
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No, no, no, especially for a 1.2Tdi. Most cars have easily accessible engine bays, the A2, for some reason, didn't but the reasons for access are the same as any other car, owner or not.

RAB
 
ecoangel said:
John L even though hose has fixed issue, longer term it may have bent selector fork. When you come to replace gearbox bearings then ensure forks are straight.
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The hose was replaced by an A2/Lupo 3L specialist and he had a good look. There was a full service done alongside the hose change but I will ask him to refill the gearbox oil and inspect. The gearbox was rebuilt a couple of years ago and so will hopefully have survived. Thanks for the info!
 
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