Hole in transmission casing

dubStrom

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2003 A4 Jetta (sold), 2010 JSW (sold), 2013 Passat 6MT traded for 2014 JSW with 6MT-TOTALED in November 2016, 2003 ALH 5MT conversion (sold), wheezing 2015 GSW/DSG and a new 2021 Tacoma Access Cab 4x4 p'up
no

the housing around the DMF is on the other side of the DSG, where it connects to the engine.

http://www.natef.org/NATEF/media/NATEFMedia/VW%20Files/DSG-SSP.pdf

is more than you want to see, probably
After reading this thread, inspecting the damage (sorry OP), then looking at the DSG manual via link (Thanks M), I feel even better about choosing 6MT. That DSG is a complicated device! And this one looks like the amount of work involved in fixing it will easily go beyond the cost of a replacement.
 

hatrick32000

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Jun 10, 2014
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bethlehem, CT
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2010 Jetta TDI sedan
I still can't see how my transmission is shot. The car was 100% normal until i parked it at the gym. Is there any sort of code i could have thrown or pressure loss from the hole that killed my starter or something? If my tranny blew up i wouldn't have been able to drive it 60 miles right before it wouldn't start. I know i'm probably in denial, but this all doesn't make sense.
 

turbobrick240

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maine
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2011 vw golf tdi(gone to greener pastures), 2001 ford f250 powerstroke
You have a gaping hole in your tranny. No amount of starters is going to fix that. Transmissions don't like running without lubricant. Start saving your pennies.
 

hatrick32000

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Location
bethlehem, CT
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2010 Jetta TDI sedan
Well yes obviously I need a new transmission, but as bad as this sounds, I really want to find a way to somewhat safely plug the hole and just drive the car if the actual internals aren't destroyed. If they weren't destroyed when I parked the car, starting it wouldn't have done anything.
 

meerschm

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2009 Jetta wagon DSG 08/08 205k buyback 1/8/18; replaced with 2017 Golf Wagon 4mo 1.8l CXBB
if you want to try,

get under the car,

clean off the hole as best you can.

(use some brake cleaner, some abrasive (file, scratchy pad....) to rough up the hole and surrounding surface, flush with more brake cleaner or alchohol)

then use some epoxy suitable for the job. (one of the JB weld or similar products)

might want to replace, or at least take a look at the filter (have to pull the battery to get to it)

then fill with proper fluid, to proper level.

you might get lucky.

just give up quick if something whines when you go to start it.

(if you want, you could turn over the engine by hand (see one of the timing belt DIYs) to make sure it moves ok.)

probably cost you $150 by the time you are done with the experiment.

more if you also need jack stands and tools.
 
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turbobrick240

Top Post Dawg
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maine
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2011 vw golf tdi(gone to greener pastures), 2001 ford f250 powerstroke
Well yes obviously I need a new transmission, but as bad as this sounds, I really want to find a way to somewhat safely plug the hole and just drive the car if the actual internals aren't destroyed. If they weren't destroyed when I parked the car, starting it wouldn't have done anything.
Unless the lubricant mostly leaked out while you were at the gym, I'd say the damage was done before you parked there. I really don't think a jb weld patch job is going to fix the problem. Let us know how it works out.
 

wilcharl

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2010 Jetta TDI BOUGHT BACK 23 NOV 16. Now owner of 2016 Jeep Cherokee
I think the JB weld would be a fun inexpensive experiment.. Just use the proper fluid. Like I said in the beginning, I fixed a cylinder head on my first car twenty years ago with JB weld. I still own the car and the head still doesn't leak..

As others have said, get it good and clean.. brake parts cleaner etc... also try to shape the JB weld up inside the hole so it has a mechanical bond along with the chemical bond of the epoxy.

Worst case, you are out 5 litres of fluid...
 

turbobrick240

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maine
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2011 vw golf tdi(gone to greener pastures), 2001 ford f250 powerstroke
I guess hattrick doesn't have much to lose with a patch attempt. Except for the uber expensive dsg fluid. I would have more optimism if the hole was higher up on the case , leaving some lubricant inside. It also sounds like it was run for quite some time empty of lubricant and seized up. I'm not too familiar with the dsg though, and suppose there may be some kind of sensor that detects low fluid level and prevented it from starting. My feeling is the trans. is shot, and cannot be effectively patched.
 

turbobrick240

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I just realized that there may be hydraulic circuits in the dsg, and it may not be seized. I mentioned cheap atf earlier in the thread. If the atf brought it back to life, you could drain that and add the correct fluid. If it didn't work, you'd only be out a few bucks on the atf.
 

hatrick32000

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bethlehem, CT
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2010 Jetta TDI sedan
I'm definitely going to waste the $120 for new fluid and $5 for some aluminum rod to braze. I mine as well waste the $120 if I'm about to spend a few thousand on this POS. I found some neat material on the web that you melt with a torch and braze over a hole and it doesn't fall in. It's probably been around forever but I never had to look up something like that. There are YouTube videos of punching a hole in a soda can then using the aluminum rod to cover it then trying to drive a stake through the repair and it doesn't go through. It's pretty awesome.
 

meerschm

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Fairfax county VA
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2009 Jetta wagon DSG 08/08 205k buyback 1/8/18; replaced with 2017 Golf Wagon 4mo 1.8l CXBB
that aluminum brazing rod is a little trickier than it looks. You still need to make it clean, and with the rod, have to get the case hot enough to bond. (but not hot enough to melt)

so practice on a couple things before you start, nothing like a practiced hand to make it look easy on a video (Plus you can edit out the ten takes where the can leaks)

smack an old gas grill cover and see if you can patch the hole. buy a cheap aluminum pan. knock a hole in it. or stop by a shop or scrap place to see if you can get some suitable item to practice on.

(and torches and an oily transmission do not sound to me like the best match)

if it was me, I would stick to the epoxy.
 
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turbobrick240

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You could sand the area clean, then use the aluminum brazing rods to weld/braze an aluminum patch on. You could do that with mapp gas without heating the case up too much. I would feel safer driving the car on long trips with a brazed on patch. Might be a little tricky doing it out of position though.
 

turbobrick240

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maine
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2011 vw golf tdi(gone to greener pastures), 2001 ford f250 powerstroke
Whatever fluid you refill it with should be drained after a very short run. With a hole that size and no belly pan, you definitely got some grime/grit inside the trans.. Even more reason to try atf first imo.
 

meerschm

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hatrick32000

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bethlehem, CT
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2010 Jetta TDI sedan
I finally got underneath the car today and the puncture definitely came from the outside. I don't remember how that happened but I'm hoping my insurance covers it. I still don't think the transmission fried but who knows. I didn't check the level yet just to be certain. I'm in denial about the transmission being blown....
 

turbobrick240

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maine
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2011 vw golf tdi(gone to greener pastures), 2001 ford f250 powerstroke
Dude, just contact your insurance company and take the car to a mechanic who knows what they're doing.
 
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