Transmission (5HP24A) Electrical Connector leaking

[TorontoA64.2]

Hi... A transmission shop has found that the electrical connector on my transmission (5HP24A) is leaking and told me that in order to fix that, I'll need to get a completely new harness, because the connector cannot be purchased separately. However, when I searched the forums and looked at the ETKA, I've found that there are 2 o-rings on the connector that are supposed to prevent transmission fluid from leaking out. I believe the part number for those 2 identical o-rings are 01V 927 322 A (or ZF part number: 0501 209 253). Does any one have any experience with this? Do I really need a new harness (which is almost $200), or can 2 o-rings that cost a total of less than $10 fix the leak from my transmission? Thanks in advance!

[ezveedub]

Originally Posted by TorontoA64.2

Hi...

A transmission shop has found that the electrical connector on my transmission (5HP24A) is leaking and told me that in order to fix that, I'll need to get a completely new harness, because the connector cannot be purchased separately.

However, when I searched the forums and looked at the ETKA, I've found that there are 2 o-rings on the connector that are supposed to prevent transmission fluid from leaking out. I believe the part number for those 2 identical o-rings are 01V 927 322 A (or ZF part number: 0501 209 253).

Does any one have any experience with this? Do I really need a new harness (which is almost $200), or can 2 o-rings that cost a total of less than $10 fix the leak from my transmission?

Thanks in advance!

The internal harness of the transmission does have an o-ring seal (not sure if one or two), but you will still have to drain and drop the transmission pan to get to it, so its not as simple as a $10 fix.

[SloopJohnB@mac.com]

Get another estimate and point out that the connector has two O-rings that can be replaced. Or talk to the technician again.

Who are you dealing with? AAMCO or a certified ZF transmission shop?

[TorontoA64.2]

Thanks for your reply. Yes, I understand - I'm going to change the transmission fluid and filter any way. I was just comparing the cost difference between replacing the entire harness against replacing just the o-rings. A new harness costs almost the same as the total of all the items I need for a transmission fluid change - filter/pan, gasket and fluid.

Also, I would like to hear others' opinions on whether the entire harness really needs to be replaced or whether replacing the 2 o-rings should eliminate the transmission fluid leak from the electrical connector.

[TorontoA64.2]

Thanks for your advice. I'll definitely ask another shop - but before I do that, I want to hear what my fellow Audi owners have to say.

I'm dealing with a major transmission chain in Toronto (I don't want to name names on the forum) similar to AAMCO. This particular location does mostly European cars, and they claim they are specialists of ZF transmissions. I guess if they didn't know about the 2 o-rings, they may not know ZF transmissions as well as they claimed to be, or they just want to make more money off of me by selling me a new harness.

I don't deny the possibility that they may charge me for a new harness but only change the 2 o-rings. I'll never find out if I don't watch them actually change the harness!

Originally Posted by SloopJohnB@mac.com

Get another estimate and point out that the connector has two O-rings that can be replaced. Or talk to the technician again.

Who are you dealing with? AAMCO or a certified ZF transmission shop?

[monkeytronic]

I haven't yet gotten around to replacing the leaking solenoid harness' 16-pin connector o-rings on the '02 A6 4.2's 5HP24A but from what I've been researching for their replacement there's no need to replace the entire solenoid harness if it's just its o-rings that are leaking.

With the transaxle pan removed, remove the external snap ring retaining the solenoid harness' 16-pin connector to the transaxle case then withdraw said connector into the case towards the valve body and drop it down to access its o-rings. Once that's done, slip off the two old o-rings, slip on the two new ones and lube them lightly with ATF or vaseline then reinsert said connector back into the transaxle case and reinstall the external snap ring.

[SloopJohnB@mac.com]

Wouldn't it depend on what the O-rings are sealing? The connector or the harness? And where the leak is coming from? Is the leak in the harness itself or around the connector?

I ask because the symptoms described are insufficient to determine whether O-ring replacement would help.

[monkeytronic]

The 100% DIYable method I used to figure out exactly where the solenoid harness connector was leaking from in my transaxle's case was to simply to spray the area around the outside of said connector with brake cleaner to completely clean off old oil, grease & grime.

Then with the ignition OFF, I disconnected said connector (it's a twist-lock affair) and visually inspected both the male and female ends involved to be completely bone dry, as they very well should be, before reconnecting said connector.

That all done, I then took the car out for a quick test drive and then repeated the visual inspection of the transaxle to verify that the leak around the solenoid harness connector had in fact reappeared and it was indeed weeping from around the outside of said connector. Therefore the o-rings in question were suspect.

All of this is to say that the OP can use this same DIY method to diagnose first-hand what and where exactly is the source of the leak without having to get a transmission shop's "opinion" of what might by awry vs. what actually is.

[TorontoA64.2]

I believe the o-rings seal the small gap between the round electrical connector and the transmission case.

The leak is from around the connector - so it's very likely the o-rings are not sealing properly. The transmission shop saw transmission fluid around the connector and immediately told me that I need a new connector - they didn't drop the pan or anything to examine the connector closely.

As I mentioned before, the transmission shop originally wanted to just replace the connector itself, however they found out later that the connector itself is not available separately, hence, I'll need to replace the entire harness. The harness will include a new connector with 2 new o-rings already installed.

Come to think of it, the shop may have mistaken my transmission for one of the newer 6-speed tiptronic transmissions like the 6HPXXX. I believe the 6HPXXX has a connector sealing "sleeve", which is readily available for purchase. The sealing "sleeve" has exactly the same function as the 2 o-rings in my transmission - the "sleeve" is probably more durable and more effective than 2 o-rings, and maybe that's why ZF used this method to seal the electrical connector in the 6HPXXX transmissions to make sure leaks around the electrical connector will be much less likely.

[TorontoA64.2]

Thanks very much for the suggestion. Yes, I think your suggestion will help confirm that the leak is really from around the connector.

I have a question though: If the leak is really within the connector itself (where the electrical pins are), wouldn't the electronics in my transmission and/or TCU be fried already (or at least make them not function normally) because of short circuits caused by the transmission fluid (I believe transmission fluid can conduct electricity)? FYI my transmission has been working flawlessly - the shifts are perfect, no slipping etc.

Originally Posted by monkeytronic

The 100% DIYable method I used to figure out exactly where the solenoid harness connector was leaking from in my transaxle's case was to simply to spray the area around the outside of said connector with brake cleaner to completely clean off old oil, grease & grime.

Then with the ignition OFF, I disconnected said connector (it's a twist-lock affair) and visually inspected both the male and female ends involved to be completely bone dry, as they very well should be, before reconnecting said connector.

That all done, I then took the car out for a quick test drive and then repeated the visual inspection of the transaxle to verify that the leak around the solenoid harness connector had in fact reappeared and it was indeed weeping from around the outside of said connector. Therefore the o-rings in question were suspect.

All of this is to say that the OP can use this same DIY method to diagnose first-hand what and where exactly is the source of the leak without having to get a transmission shop's "opinion" of what might by awry vs. what actually is.