Already did. T-case oil new and topped out. probably got too much t-case oil in there. red light still coming in. cant understand what this could be. might be time to take it to the dealer.

 

Already did. T-case oil new and topped out. probably got too much t-case oil in there. red light still coming in. cant understand what this could be. XYZ switch maybe?

Might be time to take it to dealership. Good they cant say its the parts I already replaced.

 

My transmission fluid is dissapearing for no reason. Jacked up the front end and in goes another quart and a half in the Trans. Light went off. 40 km later light comes on ! It stays this way for about 5 minutes then goes off! Then 5 minutes later comes back on ! This is really annoying not knowing if it's legit or not. I have to drive 250 miles soon.

Maybe the oil cooler is blocked with air ? Any ideas?

 

Anyone got an idea?

 

You shouldnt be losing any fluid without an obvious sign of where it is going.

Why did you need to jack the car up to set the transmission fluid level?

I don't see any mention of your model/options but you do have a 1999-04 D2 with the 4hp22/24? not a TDI with a manual?(I see you are an aussie)

The D2 4hp22/24 needs to be filled with the car running, in neutral. You fill it until fluid comes out of the fill plug. You shouldn't need to do anything about lifting/lowering the car or tricking it with height

 

Unplugged the transfer gearbox sensor with the 2 prongs and light went off. That is the temp sensor for the gearbox yea? 2 prongs on wires?

When I plugged it back in light was on. Drove 40 km and it went off and on.

The transfer gearbox has is full of gear oil.

Is the problem with the sensor that screws in or the wires that attach to it ?

 

Visually inspect the wires as far as you can follow them, look for chafes, cuts, melted spots, etc. Unplug the sensor again and put a volt meter between the 2 wires in the plug, you should read a voltage and I believe the light should come on in the Dash. That should rule out the wires being bad.

 

How did you do that?

 

the wires look old but nothing else. just old. no cuts melting or anything like that. I'l keep an eye out for a volt reader. Waiting on the transfer gear temp switch to get here from England. I got a roof rack with all kinds a crap on it. And the heaviest gear the diffs and transfer gearbox can hold. wondering if that could be making it work hard.

 

Jacked it up to stuff more fluid in. More the merrier. I got a 2000 D2..