passat 2002 gearchange problems- Arrrrrrgh !
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passat 2002 gearchange problems- Arrrrrrgh !
Hi,
I have a 2002 Passat B5 130 TDI with a 5 speed manual gearbox.
The gearchange is intermittently difficult in most gears (especially 1st, 2nd and 4th) with gear changes sometimes being impossible with some gears under certain conditions. Sometimes you can complete a journey with no significant problems.
If I can't select 1st gear from stationary, usually putting the gear into neutral, releasing the clutch and trying again fixes this problem.
2nd gear sometimes crashes on down selection after which you can only select forward gears after putting the gear into reverse.
4th gear is frequently difficult to select.
3rd and 5th gears seem okay.
It seems worse when the car has been driven for a few miles (cold oil works better).
Under heavy acceleration, change up always seems smoother with few if any problems. Problems always seem to be worse when decelerating heavily and changing down.
Now here's the problem..
1 month ago it had a new clutch and dual-mass flywheel (the clutch plate was worn and flywheel was contaminated with something). This did not cure the gearbox fault.
The gearbox has last week been stripped, cleaned and rebuilt by a gearbox specialist who maintains that there is no wear in any of the components (the car has done 150k miles) but he did change the oil (he maintained that it had hypoid oil in it). This has also made no difference. His next suggestion is to change the synchro rings, which I'm not happy doing given that they have already been checked as okay and there is no guarantee that this will cure it either !
The gear lever has about 3mm free vertical movement due to wear in the plastic ball housing mechanism. My local VW dealer service department doesn't believe that this could be the cause of the gearbox problems.
I have noticed that the gear lever moves a little when accelerating/decelerating. Also the gear lever selector measurement from the front of the plastic housing (under the gear lever gaitor) to the metal surround can only be adjusted down to 48 mm when the Haynes manual suggests a measurment of 43 mm. This suggests that the gearbox is 5mm further forward than it should be (gearbox and engine mounts are ok).
I'd appreciate any suggestions !
I have a 2002 Passat B5 130 TDI with a 5 speed manual gearbox.
The gearchange is intermittently difficult in most gears (especially 1st, 2nd and 4th) with gear changes sometimes being impossible with some gears under certain conditions. Sometimes you can complete a journey with no significant problems.
If I can't select 1st gear from stationary, usually putting the gear into neutral, releasing the clutch and trying again fixes this problem.
2nd gear sometimes crashes on down selection after which you can only select forward gears after putting the gear into reverse.
4th gear is frequently difficult to select.
3rd and 5th gears seem okay.
It seems worse when the car has been driven for a few miles (cold oil works better).
Under heavy acceleration, change up always seems smoother with few if any problems. Problems always seem to be worse when decelerating heavily and changing down.
Now here's the problem..
1 month ago it had a new clutch and dual-mass flywheel (the clutch plate was worn and flywheel was contaminated with something). This did not cure the gearbox fault.
The gearbox has last week been stripped, cleaned and rebuilt by a gearbox specialist who maintains that there is no wear in any of the components (the car has done 150k miles) but he did change the oil (he maintained that it had hypoid oil in it). This has also made no difference. His next suggestion is to change the synchro rings, which I'm not happy doing given that they have already been checked as okay and there is no guarantee that this will cure it either !
The gear lever has about 3mm free vertical movement due to wear in the plastic ball housing mechanism. My local VW dealer service department doesn't believe that this could be the cause of the gearbox problems.
I have noticed that the gear lever moves a little when accelerating/decelerating. Also the gear lever selector measurement from the front of the plastic housing (under the gear lever gaitor) to the metal surround can only be adjusted down to 48 mm when the Haynes manual suggests a measurment of 43 mm. This suggests that the gearbox is 5mm further forward than it should be (gearbox and engine mounts are ok).
I'd appreciate any suggestions !
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ahansen
Volkswagen Beetle
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Feb 24, 2008 06:44 AM
