© PEP/GoWesty 2005
 
  
 Vanagon Automatic Transaxle Failure Prevention. 
The Vanagon auto trans is a simple and strong unit with a long service life. However it does have several issues that will need attention to prevent premature failure. Read on! 

The Vanagon automatic transaxle is comprised of a automatic transmission section and a differential section. The basic design of the transaxle has not changed since it's inception in 1972. It is a three-speed design. The automatic section has the designation "010". The VW/Audi 010 automatic transmission is extremely simple, very robust, and very reliable. It was used in the Audi 4000, 5000, turbo and non-turbo versions, Passat, Rabbit, Jetta, Golf, and many more models up to about 1993. It was about that time that VW, along with every other manufacturer, switched to more efficient, but far more complicated electronically controlled 4 and 5 speed designs. 

The automatic transaxle in Vanagons has basically only two failure modes, besides just wearing out. A well maintained transaxle will last at least 250,000 miles. If it does break it is usually either the transmission oil cooler or the seals that separate the automatic transmission fluid (ATF) from the differential oil (gear oil).

Oil cooler: On all water-cooled Vanagons there is a heat exchanger mounted on the front, commonly referred to as the transmission oil cooler. This heat exchanger allows the ATF and engine coolant to flow in close proximity. Since the engine coolant warms up quickly, the heat exchanger acts to warm the ATF. Then, as the ATF becomes hotter than the coolant, the heat exchanger works in reverse and actually helps to keep the ATF cool. This heat exchanger is made of aluminum and costs about $300 installed, and should be replaced every 10 years or so, regardless of it's outward appearance, or whether it is leaking or not. That may sound like a lot of money to spend to replace a part that would by normal standards appear perfectly functional. The problem is that when the cooler fails, it does so internally. When this happens it allows the two fluids within to mix. So, the transmission gets filled will coolant, and the cooling system gets contaminated with AFT. The result is a ruined transmission ($2,000) and a ruined cooling system ($2,000). That $300 is looking pretty attractive now, isn't it? We have seen some REALLY long faces in our shop caused by this little bugger. At GoWesty, we put a new cooler on EVERY Vanagon we sell with the automatic transmission, and every rebuilt transmission we sell. Period. If you don't know whether you cooler was ever changed, CHANGE IT NOW.

Differential seals: Between the differential and automatic transmission sections there are two rubber lip seals that are placed back-to-back. Their job is to keep the ATF out of the differential, and the differential gear oil (DGO) out of the AFT. Since the ATF is under more pressure and is thinner than the DGO, the ATF usually ends up flowing into the differential section. For a while you will keep adding ATF and you will wonder where the hell it's going, 'cause it just does not leak out. It is flowing into the differential section, and will continue to do so until it fills up and starts spilling out of the breather at the top, making a huge mess. So, you should not have to EVER add ATF to your transaxle between services. If it begins to slip and you find it is low, you have to find out where it is going. If there are no external leaks, your seals have failed. You're probably thinking, "what's the big deal? ATF, DGO, BFD". ATF does not have the lubricity and viscosity required to properly lubricate the differential. So this will RUIN the final drive ring and pinion, which is THE MOST expensive part of the transaxle assembly. The good news is that these seals can be replaced without removing the entire transaxle. It is possible to remove and install the automatic transmission section in the vehicle and replace the seals. It adds about 3 hours to a normal AT service. GoWesty recommends just replacing them every third service, or 90,000 miles. 

The bottom line is that in order to get the full life out of one of these transaxles (which is quite long indeed) it is imperative to KEEP GOOD RECORDS, and DO THE MAINTENANCE! (click here for GoWesty Vanagon recommended maintenance schedule).


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