Gearbox Malfunction

[Iffy Hussain]

On 1/9/2018 at 9:19 PM, Nastech said:

Hi Guys

Sorted (I think)

I hope the information below will help others.

original fault was that my Audi A7 2011 started changing gears itself, changing from Drive to Sports mode with no demand from myself, quite dangerous.

On the dash I had the message "Gearbox Fault you can continue driving"

Called out the AA, who plugged in the computer and could see 2 gearbox faults but could not identify what they were, advised me to take to a garage.

Took it to the local Audi main dealer who eventually found fluid in the main electrical connector on the gearbox ECU and was charged £60 for the diagnosis.

Quoted just over £3k to replace the gearbox ECU and wiring harness. At this point I decided to look into it myself.

Took it to a friends garage and up on the ramp. removed the gearbox connector and yes there was the fluid inside the connector.

Here's a picture from the web, but looks identical

 

 

The fluid was obviously coolant from the colour and sweet taste (don't recommend tasting though..)

So far so good, but how did it get there???

Answer - From the Coolant control valve which is about 12" away and along the same loom.( My issue was from the coolant control valve, but it could have been another valve or sensor)

It is apparently a common fault with Audi's and an issue known to Audi- There is a Technical service bulletin out on this TSB# 2033806/7

The TSB is well worth a read.

Without getting too techie, The coolant control valve starts leaking fluid through the electrical connection point, this fluid then travels down through the harness through a process called "capillary effect" or "Wicking" and eventually gets to the gearbox electrical connector and causes mayhem to the CAN signals which control the gear selection process.

In my case, we used an airline to blow the coolant out of the gearbox connector (carefully on the gearbox end) then sprayed the connector with electrical contactor spray and reconnected the connector.

On testing the car, the error message has gone and no more random gear changing.

VCDS does not show any errors now.

I have a new Coolant control valve being fitted tomorrow ( £130 from Audi or £30 from ebay)

If the new valve is not fitted, the problem will just come back in the future.

Here's the kicker, had I gone with the Audi main dealer quote, a new harness and gearbox ECU for £3k, the quote did not include a new coolant control valve,

therefore I would have been £3k poorer and would have received a "temporary fix" as the valve would have continued to leak and eventually find it's way to the gearbox ECU connector again.

In the end it cost around £250 to get sorted.

Sorry for the long write up, I hope it helps others.

 

Hi I am new to the forum even though my account is registered since sept 2018, Think I may have the same issue. I have a 2011 Audi A6 C7 3.0 TDI. I was Driving into work this morning and went to overtake slipping it into Sport and a few seconds later got "Gearbox Malfunction -  You can continue driving" it would not let me change into any other drive mode but the power seemed ok in "D". I took it to my friend who is a mechanic in wokingham and he put on the computer and found some codes (which i will post once i can ask him) The code that he found i asked him to search online and came across this forum. He wasnt able to put it on the ramp straight away. Tomorrow he is going to take a proper look and get back to me. I will update this forum to confirm if this was the issue.

 

Many Thanks for all the posts seems like a common issue. My Father had the exact same model Audi A6 (which is still running) he sold it at 335k on the clock with no issues at all. Its nearly got 400k now :D.

[Sohail]

Hi guys. 

 

I’m new to this group and only joined because same issue to my A7 3.0 tdi 210 bhp. I’ve had the A7 for nearly 3 years now and for the past 3 months somehow water liqud is getting through the gearbox main plug and that’s causing all sort issues with the car. 

 

Luckily have a friend who has a garage and i have few times taken the plug off and cleaned out all the water but now its getting worse day by day.

 

Any one know exactly where the coolant control valve location is and what’s the part number for it please? Any help would be much appreciated 

[Iffy Hussain]

On 3/16/2019 at 6:42 PM, Sohail said:

Hi guys. 

 

I’m new to this group and only joined because same issue to my A7 3.0 tdi 210 bhp. I’ve had the A7 for nearly 3 years now and for the past 3 months somehow water liqud is getting through the gearbox main plug and that’s causing all sort issues with the car. 

 

Luckily have a friend who has a garage and i have few times taken the plug off and cleaned out all the water but now its getting worse day by day.

 

Any one know exactly where the coolant control valve location is and what’s the part number for it please? Any help would be much appreciated 

Hi Sohail 

I have literally driven my car to my friends garage with the same issue I had the connector cleaned out it worked for about week or two then tonight decide to give me issues again. My mechanic is going to replace the coolant control valve unit. The part number he gave me is 4h0121671d coolant valve. But if you can wait tomorrow he will have my car done and I can confirm if this is the exact part. Not sure if its going to be a different part number to your car because mine is the audi a6 3.0Tdi 8 speed multitronic. 

[Sohail]

Hi Iffy. Thanks much appreciated. Did you get the part changed and any news yet? 

[Iffy Hussain]

1 minute ago, Sohail said:

Hi Iffy. Thanks much appreciated. Did you get the part changed and any news yet? 

Hi sohail 

I am about to go pick it up now I will update you  shortly. 

Cheers

[Iffy Hussain]

4 hours ago, Sohail said:

Hi Iffy. Thanks much appreciated. Did you get the part changed and any news yet? 

Hi Sohail 

So I picked up my car the issue is fixed (hopefully it doesn't come back for a while). So the mechanic said this control valve is location on the dude if the gearbox at the front. It should look something like the below pictures 

 

This is where the fluid was leaking from

This is the part number for my car (audi a6 c7 2011) 

 

[Sohail]

Hi Iffy.

Much appreciated for showing me what the part looks like. Going to get my car on the ramp tomorrow and locate this part first and then go down to TPS to order a new genuine one. 

 

I’m glad you’ve been able to get this fixed and yes fingers crossed won’t be coning back again. I’ll keep you updated on my progress to see if i can get mine fixed.

 

This is the first time i’ve ever come cross a problem on the A7 other than that been faultless. 

 

Thanks 

[Iffy Hussain]

On 3/20/2019 at 5:36 PM, Sohail said:

Hi Iffy.

Much appreciated for showing me what the part looks like. Going to get my car on the ramp tomorrow and locate this part first and then go down to TPS to order a new genuine one. 

 

I’m glad you’ve been able to get this fixed and yes fingers crossed won’t be coning back again. I’ll keep you updated on my progress to see if i can get mine fixed.

 

This is the first time i’ve ever come cross a problem on the A7 other than that been faultless. 

 

Thanks 

Hope you got the issue sorted.

I was driving up to birmingham this afternoon and it seems like the issue has come back again. I had the cruise control on at 70 and i came up to a slight hill which required the car needing bit more power so it automatically accelerates but instead of keeping the speed steady it seems like its popped out of gear and just red lined.This happened twice it felt like it wanted to go into gear but couldnt so i took cruise control off and it was ok after that.  

The message i have on the dash is the exact same  "Gearbox Malfunction you can continue driving" I will have it connected to the computer and see if its still the same error.

What i think has happened is the Mechanic has changed the control valve unit and cleaned out the plug, I have a feeling there may have been still some coolant in the cable which has traveled up to the ecu connector/plug again. I am hoping i can get back to london without any issues otherwise its going to be a call to RAC on my way back. I will keep you updated when i have got it checked by a mechanic again.

[jedyaqub]

On 3/30/2019 at 9:57 PM, Iffy Hussain said:

Hope you got the issue sorted.

I was driving up to birmingham this afternoon and it seems like the issue has come back again. I had the cruise control on at 70 and i came up to a slight hill which required the car needing bit more power so it automatically accelerates but instead of keeping the speed steady it seems like its popped out of gear and just red lined.This happened twice it felt like it wanted to go into gear but couldnt so i took cruise control off and it was ok after that.  

The message i have on the dash is the exact same  "Gearbox Malfunction you can continue driving" I will have it connected to the computer and see if its still the same error.

What i think has happened is the Mechanic has changed the control valve unit and cleaned out the plug, I have a feeling there may have been still some coolant in the cable which has traveled up to the ecu connector/plug again. I am hoping i can get back to london without any issues otherwise its going to be a call to RAC on my way back. I will keep you updated when i have got it checked by a mechanic again.

Hi Iffy - I have the same issue with the cooling oil valve  did you get yours sorted? What was the outcome?

Address 02: Auto Trans (J217)       Labels:| 0B5-927-156.clb

   Part No SW: 4G1 927 156 C    HW: 0B5 927 156 F

   Component: 0B5 30 TDIRdW H10 0001 

   Revision: --H10---    Serial number: 0000001037

   Coding: 000001

   Shop #: WSC 02391 785 00200

   ASAM Dataset: EV_TCMDL501 A02087

   ROD: EV_TCMDL501.rod

   VCID: 2D07F57AFD99373F05B-8078

 

1 Fault Found:

8030 - Cooling Oil Valve

          P179D 00 [040] - Electrical Malfunction

          Intermittent - Confirmed - Tested Since Memory Clear

             Freeze Frame:

                    Fault Status: 00000001

                    Fault Priority: 2

                    Fault Frequency: 2

                    Reset counter: 40

                    Mileage: 103330 km

                    Date: 2019.04.13

                    Time: 09:19:53

 

                    Engine speed: 905 /min

                    Transmission input speed: 905 /min

                    Transmission output speed: 0 /min

                    Engine torque: -8 Nm

                    Transmission fluid temperature: 3 °C

                    Accelerator position: 0.0 %

                    Clutch status: Beide Kupplungen offen

 

[Whitters]

I too have a 2011 A7 with the same symptoms and a transmission error fault code P179F00, saying the driving stage sensor G676 cannot detect the engaged gear correctly.  I'm told this is a gearbox stripdown to replace the sensor.  

I wonder if it's all related to fluid in yge harness causing havoc to the eco.

Has anyone else experienced this fault and how was it rectified?

Regards Paul 

[tomaxass]

On 1/9/2018 at 11:19 PM, Nastech said:

Hi Guys

Sorted (I think)

I hope the information below will help others.

original fault was that my Audi A7 2011 started changing gears itself, changing from Drive to Sports mode with no demand from myself, quite dangerous.

On the dash I had the message "Gearbox Fault you can continue driving"

Called out the AA, who plugged in the computer and could see 2 gearbox faults but could not identify what they were, advised me to take to a garage.

Took it to the local Audi main dealer who eventually found fluid in the main electrical connector on the gearbox ECU and was charged £60 for the diagnosis.

Quoted just over £3k to replace the gearbox ECU and wiring harness. At this point I decided to look into it myself.

Took it to a friends garage and up on the ramp. removed the gearbox connector and yes there was the fluid inside the connector.

Here's a picture from the web, but looks identical

 

 

The fluid was obviously coolant from the colour and sweet taste (don't recommend tasting though..)

So far so good, but how did it get there???

Answer - From the Coolant control valve which is about 12" away and along the same loom.( My issue was from the coolant control valve, but it could have been another valve or sensor)

It is apparently a common fault with Audi's and an issue known to Audi- There is a Technical service bulletin out on this TSB# 2033806/7

The TSB is well worth a read.

Without getting too techie, The coolant control valve starts leaking fluid through the electrical connection point, this fluid then travels down through the harness through a process called "capillary effect" or "Wicking" and eventually gets to the gearbox electrical connector and causes mayhem to the CAN signals which control the gear selection process.

In my case, we used an airline to blow the coolant out of the gearbox connector (carefully on the gearbox end) then sprayed the connector with electrical contactor spray and reconnected the connector.

On testing the car, the error message has gone and no more random gear changing.

VCDS does not show any errors now.

I have a new Coolant control valve being fitted tomorrow ( £130 from Audi or £30 from ebay)

If the new valve is not fitted, the problem will just come back in the future.

Here's the kicker, had I gone with the Audi main dealer quote, a new harness and gearbox ECU for £3k, the quote did not include a new coolant control valve,

therefore I would have been £3k poorer and would have received a "temporary fix" as the valve would have continued to leak and eventually find it's way to the gearbox ECU connector again.

In the end it cost around £250 to get sorted.

Sorry for the long write up, I hope it helps others.

 

you save my money 🙂 was the same problem too

[Immy]

Hi, bought 2011 Audi A4 2.0 tfsi auto quattro two months. 106,000 miles been fine however today the gearbox malfunction, you can continue driving message appeared. I'm not a hands on guy wanted advise as to what should i do. Take it to Audi main dealer or to an Audi & VW specialist. The car drives fine no hesitation but the engine management remains on dash board. Any advice will be greatly appreciated.

[Hensoldt]

Can someone please explain to me where I can find the gearbox connector? How can I reach it? A picture says more then a thousand words. Just saying. / Patrik 

[Kestas]

Hi guys am have Audi A7 2012 3.0 tdi Quatro and have problem with gearbox intercooler start leaking and antifreeze go to gear box any sugestons ????? good mechanic in London propably I need other gearbox 

[Walshy22]

On 1/9/2018 at 9:19 PM, Nastech said:

Hi Guys

Sorted (I think)

I hope the information below will help others.

original fault was that my Audi A7 2011 started changing gears itself, changing from Drive to Sports mode with no demand from myself, quite dangerous.

On the dash I had the message "Gearbox Fault you can continue driving"

Called out the AA, who plugged in the computer and could see 2 gearbox faults but could not identify what they were, advised me to take to a garage.

Took it to the local Audi main dealer who eventually found fluid in the main electrical connector on the gearbox ECU and was charged £60 for the diagnosis.

Quoted just over £3k to replace the gearbox ECU and wiring harness. At this point I decided to look into it myself.

Took it to a friends garage and up on the ramp. removed the gearbox connector and yes there was the fluid inside the connector.

Here's a picture from the web, but looks identical

 

 

The fluid was obviously coolant from the colour and sweet taste (don't recommend tasting though..)

So far so good, but how did it get there???

Answer - From the Coolant control valve which is about 12" away and along the same loom.( My issue was from the coolant control valve, but it could have been another valve or sensor)

It is apparently a common fault with Audi's and an issue known to Audi- There is a Technical service bulletin out on this TSB# 2033806/7

The TSB is well worth a read.

Without getting too techie, The coolant control valve starts leaking fluid through the electrical connection point, this fluid then travels down through the harness through a process called "capillary effect" or "Wicking" and eventually gets to the gearbox electrical connector and causes mayhem to the CAN signals which control the gear selection process.

In my case, we used an airline to blow the coolant out of the gearbox connector (carefully on the gearbox end) then sprayed the connector with electrical contactor spray and reconnected the connector.

On testing the car, the error message has gone and no more random gear changing.

VCDS does not show any errors now.

I have a new Coolant control valve being fitted tomorrow ( £130 from Audi or £30 from ebay)

If the new valve is not fitted, the problem will just come back in the future.

Here's the kicker, had I gone with the Audi main dealer quote, a new harness and gearbox ECU for £3k, the quote did not include a new coolant control valve,

therefore I would have been £3k poorer and would have received a "temporary fix" as the valve would have continued to leak and eventually find it's way to the gearbox ECU connector again.

In the end it cost around £250 to get sorted.

Sorry for the long write up, I hope it helps others.

 

Hello, 

Thanks for all the detail! I recently had my A7 in for a good bit of work in October, gearbox service included, and a suspected coolant leak (needed two top ups in 6 months).

Was also getting the gearbox malfunction warning very sporadically. 6 weeks later, coolant level warning AGAIN, and low and behold nearly empty tank! Leak clearly still there, but more recently in last 4 days more occurrences of gearbox malfunction warning, and today it happened and couldn't move the car and had to turn on and off a few times to get her going again. Based on what you've said above, I am wondering if something similar is happening....

[Inflames]

Hi all, this thread has been an interesting read, whilst I have been doing some research into this issue.  Before I purchase a A7 in the new year, I even started a thread asking about it sorry should have used the search function first.

[Kashee]

On 12/7/2022 at 9:02 AM, Walshy22 said:

Hello, 

Thanks for all the detail! I recently had my A7 in for a good bit of work in October, gearbox service included, and a suspected coolant leak (needed two top ups in 6 months).

Was also getting the gearbox malfunction warning very sporadically. 6 weeks later, coolant level warning AGAIN, and low and behold nearly empty tank! Leak clearly still there, but more recently in last 4 days more occurrences of gearbox malfunction warning, and today it happened and couldn't move the car and had to turn on and off a few times to get her going again. Based on what you've said above, I am wondering if something similar is happening....

Getting the exact same issue on my A7 3.0 TDI. I am luckily not experiencing performance issues. Yet.

Did you get it fixed? 

Can anyone recommend a trusted garage guy for diagnosing the issue around Reading? 

[Passerby]

On 1/9/2018 at 9:19 PM, Nastech said:

Hi Guys

Sorted (I think)

I hope the information below will help others.

original fault was that my Audi A7 2011 started changing gears itself, changing from Drive to Sports mode with no demand from myself, quite dangerous.

On the dash I had the message "Gearbox Fault you can continue driving"

Called out the AA, who plugged in the computer and could see 2 gearbox faults but could not identify what they were, advised me to take to a garage.

Took it to the local Audi main dealer who eventually found fluid in the main electrical connector on the gearbox ECU and was charged £60 for the diagnosis.

Quoted just over £3k to replace the gearbox ECU and wiring harness. At this point I decided to look into it myself.

Took it to a friends garage and up on the ramp. removed the gearbox connector and yes there was the fluid inside the connector.

Here's a picture from the web, but looks identical

 

 

The fluid was obviously coolant from the colour and sweet taste (don't recommend tasting though..)

So far so good, but how did it get there???

Answer - From the Coolant control valve which is about 12" away and along the same loom.( My issue was from the coolant control valve, but it could have been another valve or sensor)

It is apparently a common fault with Audi's and an issue known to Audi- There is a Technical service bulletin out on this TSB# 2033806/7

The TSB is well worth a read.

Without getting too techie, The coolant control valve starts leaking fluid through the electrical connection point, this fluid then travels down through the harness through a process called "capillary effect" or "Wicking" and eventually gets to the gearbox electrical connector and causes mayhem to the CAN signals which control the gear selection process.

In my case, we used an airline to blow the coolant out of the gearbox connector (carefully on the gearbox end) then sprayed the connector with electrical contactor spray and reconnected the connector.

On testing the car, the error message has gone and no more random gear changing.

VCDS does not show any errors now.

I have a new Coolant control valve being fitted tomorrow ( £130 from Audi or £30 from ebay)

If the new valve is not fitted, the problem will just come back in the future.

Here's the kicker, had I gone with the Audi main dealer quote, a new harness and gearbox ECU for £3k, the quote did not include a new coolant control valve,

therefore I would have been £3k poorer and would have received a "temporary fix" as the valve would have continued to leak and eventually find it's way to the gearbox ECU connector again.

In the end it cost around £250 to get sorted.

Sorry for the long write up, I hope it helps others.

 

Hi, I know this is a long time ago, but I just wanted to know whether the problem with your car came up again after the fix you described. It seems I'm having similar issues with my A5.

[Insomniac]

On 1/9/2018 at 9:19 PM, Nastech said:

Hi Guys

Sorted (I think)

I hope the information below will help others.

original fault was that my Audi A7 2011 started changing gears itself, changing from Drive to Sports mode with no demand from myself, quite dangerous.

On the dash I had the message "Gearbox Fault you can continue driving"

Called out the AA, who plugged in the computer and could see 2 gearbox faults but could not identify what they were, advised me to take to a garage.

Took it to the local Audi main dealer who eventually found fluid in the main electrical connector on the gearbox ECU and was charged £60 for the diagnosis.

Quoted just over £3k to replace the gearbox ECU and wiring harness. At this point I decided to look into it myself.

Took it to a friends garage and up on the ramp. removed the gearbox connector and yes there was the fluid inside the connector.

Here's a picture from the web, but looks identical

 

 

The fluid was obviously coolant from the colour and sweet taste (don't recommend tasting though..)

So far so good, but how did it get there???

Answer - From the Coolant control valve which is about 12" away and along the same loom.( My issue was from the coolant control valve, but it could have been another valve or sensor)

It is apparently a common fault with Audi's and an issue known to Audi- There is a Technical service bulletin out on this TSB# 2033806/7

The TSB is well worth a read.

Without getting too techie, The coolant control valve starts leaking fluid through the electrical connection point, this fluid then travels down through the harness through a process called "capillary effect" or "Wicking" and eventually gets to the gearbox electrical connector and causes mayhem to the CAN signals which control the gear selection process.

In my case, we used an airline to blow the coolant out of the gearbox connector (carefully on the gearbox end) then sprayed the connector with electrical contactor spray and reconnected the connector.

On testing the car, the error message has gone and no more random gear changing.

VCDS does not show any errors now.

I have a new Coolant control valve being fitted tomorrow ( £130 from Audi or £30 from ebay)

If the new valve is not fitted, the problem will just come back in the future.

Here's the kicker, had I gone with the Audi main dealer quote, a new harness and gearbox ECU for £3k, the quote did not include a new coolant control valve,

therefore I would have been £3k poorer and would have received a "temporary fix" as the valve would have continued to leak and eventually find it's way to the gearbox ECU connector again.

In the end it cost around £250 to get sorted.

Sorry for the long write up, I hope it helps others.

 

Hi,

 

Thanks for your very useful post, appreciate from a few years ago.

Can I ask how your car is doing now, and which particular garage you had the work done at?

thanks again