Replacing Automatic Transmission Fluid (ATF)

Hi - I've acquired a 2001 996.1 C4 Cab Tiptronic with the A96/30 tip box. As routine maintenance (although in my view the 1st to 2nd gear was thumping quite hard), I've tried to follow the Pelican Parts / 101 Jobs procedure for replacing the ATF fluid. The procedure has you: Removing the sump, replacing the filter, buttoning it all back up then filling until the filler cap overflows. Warm the engine up until the sump is reading between 30-40 degrees centigrade, open the filler and top up. When topped up to keep engine running while you cycle (with foot on brake) through reverse, 1st and 2nd gears - topping up as necessary. Then all done. I followed this, putting initially about 3l into the sump at first fill ... but when I got to the end of step 2 and opened the filler to top up, ATF fluid came pouring out (all over me) ... I quickly did up the cap ! I then decided to do step 3 anyway to see if this made a difference - it didn't, same again, when I opened the filler cap the ATF just poured out. So I've now removed 5-6l and only have around 2.5l replaced ! I did note that the temperature at the back of the sump was a little less than at the front where the filler cap is (you check using an infrared thermometer). The instructions are very clear to say to put the on the level, so I did wonder if this might be the issue. I use quickjacks which are bang on. It's difficult to tell if the car is sitting on them level but if there is a difference it would be extremely minimal. The other point I've noted that is different is that the filter I took off had a plastic 'nozzle' on the shiny metal side which sits over the large exit hole from the filter, which is held in place by a metal band. This nozzle isn't on the replacement filter. There is just a hole which the nozzle fits over. The pictures ishown in the Pelican Parts site don't have the nozzle in place and it isn't mentioned. But because it was on the one I took off, I transferred it onto the new one. Not sure why this would make a difference but it is essentially the same now as before I started. The instructions are also very clear that you must use the correct fluid - all the intel points to using ZF Lifeguard 5 fluid, as the A96/30 tip box should be the last of the ZF boxes. I got hold of Febi Bilstein 194472, which is Lifeguard 5 rated and listed against this model on the Bistein website - so I'm hoping this is correct (it's the most expensive oil known to man). Has anyone had a similar experience or could hazard a guess at why I haven't been able to fill the sump back with the 5-6l that I think it should need? Thx in advance

This one of those threads where we really miss Skip, Hope he is feeling better and will be back here soon...!!! Get well soon Skip.... Skip would have told you exactly whats going on, his knowledge of the tip tranny is impressive. Might want to do a search on the ZF trans using Skip as the author_ Porschetech3 My 02 uses the Mercedes tip so I'm no help here sorry. All I can say is the ZF tranny is used in many different cars from that era and should be able to research google it till you find your solution, its out there somewhere....

I have a 1999 C2 with the ZF5HP19 tip in it, and I have just recently gone through the empty/replace filter/re assemble / re fill procedure. It sounds like you did the right things - you left the engine running while you removed the filler plug, correct? And you are checking via the filler plug not via the drain plug, correct? In my tip, the drain pan has a filler plug and a drain plug, and you have to check the fill level via the fill plug, while the engine is running and at temperature. My filter has more of a snorkel type apparatus on the bottom surface, over the intake hole. I think this is to get the intake into the trans fluid, so air bubbles are not sucked in. Not sure what your filter looks like, but it sounds like it may be different. It is probably important that the filter intake is immersed in the trans fluid or else it will not be able to pull it into the trans and circulate it via the pump. Here is the filter I used: https://www.google.com/aclk?sa=L&ai=...BAgKEBk&adurl= Maybe your intake is not getting into the fluid, and so when you start the engine, the trans is pumping fluid out of the torque converter and into the pan, but is not able to pull any fluid up into the filter, so it is basically emptying itself into the pan? If you want to call me, I am happy to try to help you via phone and facetime. I can show you the filter I removed, for example. Yes, it is important to use the correct Lifeguard 5 fluid or equivalent, imho.

Thanks for the advice ... I worked out that the chinesium infrared thermometer was not reading the temp properly and was running too hot. Instead used my code reader to read actual temp of gearbox and all fine ... very fine margins on this one! Now performed the double flush and super smooth gearbox again.

I just did this procedure a few weeks ago, very easy, I've been doing it on Audi's for a long time. Here is probably the best video you can find. It's on the Rockauto page for the ZF hydraulic fluid. https://www.rockauto.com/en/moreinfo...=11387&jsn=591 From my website, but it's for an Audi, same thing: https://www.audipages.com/Tech_Artic...servicing.html