Changin ATF on 5KT

[Aleksander Mierzwa <alex@matrix.com.pl>]

Hi List!

I just changed ATF in the slushbox of my 87 5KT and thought I could
share my experiences with anyone who might want to do this.
	First I decided to check the operation of the electric oil pump
I bought for $15. It works, but I'll have to replace both inlet and
outlet hoses - they are too short and too unflexible. Then I tried to
unscrew the dipstick tube from the pan. No luck, it's seized solid. So I
removed the 19mm transmission to engine bolt that also holds the tube
and removed the pan with the tube attached. It helps to have the vehicle
over an inspection pit or to jack it as high as possible - otherwise you
won't be able to remove the pan from under the car if the tube is still
attached. The fluid started dripping from the pan, but I tilted it to
one corner and it was quite easy to catch the fluid into the container.
I moved the pan to the side and proceeded to unbolt the filter cover. No
big deal, two Philips screws. Discarded the old filter gasket. It was
very tired. When doing this job, you can eventually reuse the pan
gasket, but always buy new filter gasket. Beware: after removing the
filter another 0.5 litres of fluid will drain from the tranny, so keep
the container ready. I cleaned the cover and filter with ethylene
spirit. One note here: although all manuals say to just clean the
filter, I think it is actually good idea to  renew it. There was lot of
very small particles left in the filter impossible to remove.
Reassembled the filter and cover and bolted it back to the tranny. If
you don't have inspection pit and you are working lying under the car,
now it is good idea to cover the working area with newspapers or towels.
When cleaning and reinstalling the pan the dirt from the floor almost
magically gets into the pan, which is a no-no. Refitting the pan turned
out to be the toughest part. The new gasket was slipping off the pan
while I was trying to get the dipstick tube back into place and not
damage the CV boot with the tube bracket. I was sure the pan gasket will
leak. It doesn't. Hey, what have I overlooked? ;-) I can't get the
gasket into place, can't get the pan into place, I'm working lying under
the car, I'm dirty and tired. After finally bolting it back it doesn't
leak. It's not normal ;-) ;-) ;-)
OK, refilling the tranny is failry straightforward job. Just remember -
when cold the fluid level should be below minimum mark. It will expand a
lot when at normal temperature, when it should be between the marks. Of
course, I overfilled it a little :-)
One note on synthetic ATF - I used semi-synthetic fluid manufactured by
Dutch company VAT (the really good stuff like Redline hasn't showed up
here yet). The best thing about it is that my tranny shifts very smooth
even when very cold. Before the change, it was shifting very violently
until it warmed up. Highly advisable.

Aleksander Mierzwa
Warsaw, Poland
mailto:alex@matrix.com.pl
87 Audi 5000CS turbo (mine)
88 Renault Medallion wagon (mom's)
91 mountain bike (just in case both cars broke at the same time :-)