Morning All

I posted on this a little while back long with another question and didn't really get much in the way of a reply, now it seems a little worse I thought I'd try again.

I have an 02 plate 1.9 TDI Elegance, it's done about 150k miles, and still going strong.

However I've started experiencing problems selecting 3rd or 4th gear. Weirdly it's not every time, it's not always going between the two, ie can be a problem from 2nd to 3rd, or 3rd to 4th, or 4th to 3rd.

The actualy problem seems like it goes part of the way into the gate, but doesn't engage, if you take it back to neutral and try again it might be OK, or might take a couple of attempts, sometime, you have to give up. Sometimes it seems that going to neutral, releasing and re-engaging the clutch helps.

As I say it's only 3rd and 4th, and it's not always a problem.

When the engine is off I've tried selecting gears using the metal lump on the cam in the engine bay, sometimes it binds here too.

Anyone any idea on this, would the re-alignment procedure in the Haynes help?

Thanks

Tom

Spray the linkage with WD40 on top of the gearbox then have a watch of this http://www.youtube.com/watch?v=tp9ggefOjAE

If it frees up, try WD40 for a couple of days then reset it again.

Try some lithium spray grease for longer lasting results.

Although the gearbox is "sealed for life" I change mine every 100,000 miles which frees it up a bit more.

Spray the linkage with WD40 on top of the gearbox then have a watch of this http://www.youtube.com/watch?v=tp9ggefOjAE

If it frees up, try WD40 for a couple of days then reset it again.

Try some lithium spray grease for longer lasting results.

Although the gearbox is "sealed for life" I change mine every 100,000 miles which frees it up a bit more.

OK, I gave the linkage a quick spray and released the locking rings to find the 3 fingers in each case were stuck tight against the cable. So I gave them a spray and left them over night. They were still stuck the following morning so I used to a screwdriver to gently prize them open. Performed the re-alignment procedure and ....

.... well the gear changes (across the board) are smoother and quieter than they were. Sadly however my 3rd/4th issues are not fixed.

Any further ideas?

One thing I did think of the other day while sat bored in a car park with the gear stick gaitor up admiring the workings...if I release the locking rings again and lift the two connector clean away from the cable, if I then work through the gears and I find any issue it must be in the selector. Also while in bits like this I can try going through the gears from within the engine bay.

I did notice that the up/down action on the gear box was a little rough, but from what I recall 3rd/4th is a rotate action not an up/down.

Tom

I would definately try changing the gearbox oil. I did on my car at about 85k and the gear change became noticably smoother. Also I would get the proper VW oil from the dealer or TPS as the gearboxes seem very picky over the type of oil used.

Oh and make sure you fill it up with the car level! - Someone posted a thread about changing the gearbox and used a funnel and piece of hosepipe to make filling the box up easier, access to the fill point is crap.

Edited 15 November, 201015 yr by trundlenut

I would definately try changing the gearbox oil. I did on my car at about 85k and the gear change became noticably smoother. Also I would get the proper VW oil from the dealer or TPS as the gearboxes seem very picky over the type of oil used.

Oh and make sure you fill it up with the car level! - Someone posted a thread about changing the gearbox and used a funnel and piece of hosepipe to make filling the box up easier, access to the fill point is crap.

It's weird, I got the car with 150k on the clock, drove it back about 80 miles, drove it for many weeks locally no problem, did a couple of 60+ mile journeys no issue, then while it started playing around, but only ever in those two gears.

While I was fixing the aux tensioner and changing the oil & filter I noticed that under the gear box there is a plate with VW moulded into it, held in place by two bolts, this was rather oily, so I tightened, though was pretty tight anyway, checked the gearbox oil and didn't get a dribble so added a bit.

I guess that VW plate is where you drain the gearbox? I assume there would be a gasket behind it? At the moment I'm all out of ideas on this one, but I need to get it fixed because it affects driving, you never know when you'll have trouble getting into 3/4 so you have to drive with all the dawdlers.

Tom

Yes the drain plug is on the bottom and the fill plug in on the front and there is a wiggly pipe in front of the fill plug. You need a 17mm hex socket to undo the plugs. There isn't a gasket behind the plugs.

Yes the drain plug is on the bottom and the fill plug in on the front and there is a wiggly pipe in front of the fill plug. You need a 17mm hex socket to undo the plugs. There isn't a gasket behind the plugs.

I did not have a 17mm hex socket, so I used a 17mm nut and bolt welded together, and then used that with a 17mm socket - cost saving to the last penny

I did not have a 17mm hex socket, so I used a 17mm nut and bolt welded together, and then used that with a 17mm socket - cost saving to the last penny

For some unknown reason I do have an ancient 17mm Allan Key, that's what I used when I topped it up.

Tom