DrewRedA4

Thanks. Will do. You guys are great.

MarkChai

Sorry to hear that. I'm in a similar boat because of a different bearing (or lack thereof!)

DrewRedA4

Well the plot thickens. I have the trans on the floor right now, ready to put in the replacement unit. (Bought used - thanks Dennis!)
The noise seems to be coming from the ring and pinion (again, i think the pinion bearing has failed, causing the entire front of the output shaft to drop, giving me about 3/4 inch of backlash.) Anyway, there is also a decent noise from the TorSen center diff unit.
After I get this replacement box up in there I am going to crack open the original gearbox and post photos of the damage. Stay tuned...
-Andrew

DrewRedA4

The prod. date on my car was Jan 8, 2002.
The code on my trans is GBT. GBT was for production date 7/02->5/03, according to ETKA.
The code on the replacement trans is FPT. FPT was for Oct '01->6/02.
You can't make this stuff up.
-Andrew

DrewRedA4

So i tore into the gearbox after work today. Found there was severe pitting on one of the rollers in the tapered roller bearing that supports the pinion shaft - just like I expected. The Torsen was fine (as usual), the driven gearset was fine, the input shaft and gearset was fine.

I just need to get a new pinion bearing, drive the old race out, the new race in, set the pinion depth right-proper again and then I'll have a nice gearbox with 26K miles on it for sale.

Anybody shopping?

Photos in:
Galling in this one particular roller. The hardening chunks probably did the rest of the damage on the other rollers.
<img src="http://pictureposter.audiworld.com/124906/p1000810.jpg">

No gear damage; even the pinion bearing race was clean &amp; smooth. It will get replaced anyway.
<img src="http://pictureposter.audiworld.com/124906/p1000815.jpg">

No abnormal wear on the ring gear. Thank God.
<img src="http://pictureposter.audiworld.com/124906/p1000822.jpg">

Where the output/pinion shaft sits, for those that care:
<img src="http://pictureposter.audiworld.com/124906/p1000824.jpg">

The diff housing. Notice the fuzzies on the magnet. The drain plug was pretty much the same, before I cleaned it.
<img src="http://pictureposter.audiworld.com/124906/p1000829.jpg">

diagnosticator1

What was the warranty status/refusal reason?

I would love to hear AoA's "theory" to justify refusal/why the warranty was not applicable if that was ever investigated or discussed.

DrewRedA4

No warranty - I went over on time. And anyway, the machismo side said I can fix it all myself anyway.

I will be writing a letter with photos, oil sample, the bearing, tranny serial number, production dates, etc...

-Ddrew

ryanneve

This bearing out of my 03 A4 1.8 has 90k easy miles on it.
Dealer said it was tire noise and once it was really bad I was no longer under warranty.

drgertol

Just came across this thread. Found a 2005 A4Q with 6speed manual in June that was perfect except for some noise in the drivetrain. First shop said cupped tires. Second shop said drive shaft bearing. Preferred shop said transmission, definitely. Replaced with a salvaged transmission, and it's near perfect now. Still need to find out what was at fault in the original transmission.