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Post by dooroy on May 20, 2015 11:20:04 GMT 1
A friend has a 1999 Golf 1.9 Tdi with about 135K mls on the clock.
Last week while travelling on the motorway it jumped out of 5th gear .
Since then it won't stay in 5th at all .
I changed the bearing in 'selector tower' as it was very loose (all the bearings had gone out of the cage ) and changed the oil in the box (old oil was very dirty and thin) .
Gear change has improved considerably as up to that he was finding it difficult to engage some gears.
Set up cables and gear lever again using pin in gear lever etc .
However it still won't remain in 5th so must be be an internal problem.
It didn't start off being intermittent and then getting worse as some problems do .
Any ideas as to what may be possible to sort this - or is a SH box his best option ?
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Post by Noberator on May 20, 2015 12:33:03 GMT 1
A friend has a 1999 Golf 1.9 Tdi with about 135K mls on the clock. Last week while travelling on the motorway it jumped out of 5th gear . Since then it won't stay in 5th at all . I changed the bearing in 'selector tower' as it was very loose (all the bearings had gone out of the cage ) and changed the oil in the box (old oil was very dirty and thin) . Gear change has improved considerably as up to that he was finding it difficult to engage some gears. Set up cables and gear lever again using pin in gear lever etc . However it still won't remain in 5th so must be be an internal problem. It didn't start off being intermittent and then getting worse as some problems do . Any ideas as to what may be possible to sort this - or is a SH box his best option ? I'm thinking maybe the selector fork for fifth is stuck or broken.  Gearbox oil level ok still after being changed. |
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Post by Joepublic on May 20, 2015 15:48:46 GMT 1
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Post by dooroy on May 20, 2015 22:15:19 GMT 1
Thanks for replies .
When I drained the gearbox I let it flow for quite a while . However when I refilled the box it only took about one and a half litres - I thought it should take 2 at least . Checked level again after a drive and it was still just at level of filler hole .
Any reason why it should not take the full 2 litres ?
That PDF on changing 5th gear is very well done . However I would have to first check the price of the parts - they could cost silly money .
If I remove end plate what should I be looking out for - the gears not engaging fully ?
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Post by Joepublic on May 21, 2015 8:09:54 GMT 1
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Post by dooroy on May 21, 2015 11:30:24 GMT 1
Those links are very helpful , thanks  . I think my best course of action is to take off the endplate first of all - could be a problem with selector arm etc. Box wasn't low in oil but as I said earlier the oil looked a dirty brown and was very thin - so probably not providing much lubrication. And it would appear that poor/lack of lubrication could have damaged other parts - meaning a SH replacement would be best option . Still haven't figured out why it only took about 1.5 litres to get it back up to the correct level . Will post back on how it goes . |
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Post by Joepublic on May 21, 2015 13:30:03 GMT 1
I'm not saying this is the same case, but mk2 gti 8valves had a taller inlet manifold than the carb models and due to bonnet clearance issues they fitted different mounts for clearance that canted the engine further back. In doing so this lowred the level plug hole only allowing 1.5l instead of 2l on the carb models, so the way around this was to ignore the level plug and pour 2l in via the speedo drive.
I'm not saying this is similar here, but it would explain the shortfall
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Post by wheelnut on May 22, 2015 0:11:36 GMT 1
Still haven't figured out why it only took about 1.5 litres to get it back up to the correct level . . . Joe Public may have beaten me to it. Certain Opel/Vauxhall gearboxes had to be filled from the top via a vent or speedo drive. Filling through the level plug did not work. (don't know if they are still the same). I wonder if your VW box is the same? |
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Post by dooroy on May 22, 2015 18:00:16 GMT 1
He has owned this Golf for a long time - so would say it is as it should be .
Hadn't heard of filling VW boxes through the speedo drive or top vent - so this could mean that this box has been running with a low oil level for years.
This could have led to the present problem and box probably gone beyond help if thats the case.
Will see how it looks when end plate removed .
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Post by Deleted on May 22, 2015 20:26:02 GMT 1
There is factory sequence to draining manual boxes or not all oil will be drained , its not hard to figure out . same with filling  |
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Post by dooroy on May 22, 2015 20:41:37 GMT 1
'factory sequence'
What is that ?
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Post by Joepublic on May 23, 2015 19:30:09 GMT 1
He has owned this Golf for a long time - so would say it is as it should be . Hadn't heard of filling VW boxes through the speedo drive or top vent - so this could mean that this box has been running with a low oil level for years. This could have led to the present problem and box probably gone beyond help if thats the case. Will see how it looks when end plate removed . There's a lad on another forum importing new 5th gear sets from italy for £115 posted, if you're interested I'll PM you a link. |
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Post by dooroy on May 23, 2015 22:48:19 GMT 1
Thanks Joepublic , that would be great .
Owner is considering his options - SH box or repair his own.
Problem with SH is it could do the same thing after a few months IMHO.
Couldn't get across to VW dealer on the phone what I wanted to price up - so will have to call in .
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Post by dooroy on May 25, 2015 23:03:00 GMT 1
Just to update .
Took the end of the box to find 5th gear had a lot of play in it - wobbling from side to side .
When pulled off the roller bearing was badly worn and had in fact worn a groove in the shaft .
So search on now for SH box .
Thanks for link joepublic
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Gearbox oil level ok still after being changed. 
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