Author Topic: 02J 5 gear problem, please help (Read 12477 times)

Justin · « **on:** March 04, 2008, 04:55:17 am »

Hey guys I was driving home from work yesterday when I merged onto one highway from another (both 70 mph roads) when I got up to 60 mph I went into 5th and about a 1/4 mile after it went into 5th I had a shudder and it popped out of gear. I put it back in and had to physically hold it in gear if I was putting a load on it, if I backed off the throttle then I could feel the trans pulling the shifter into 5th.

got home thought there was something in the way so I moved some things and same thing. thought my shift cable had stretched so I shortened it up all the way for a quick and easy test. still wants to pop out of gear. Drove into work today (35 mile commute) and about half way even with me holding it in 5th it shudders and pops out. so I ran slow and in 4th to make it in.

so what is wrong and what do I need to do to fix it, I am assuming that its my shift forks since for a while they have been bent for 1st gear, is this the same set of forks for 1st and 5th?

thanks in advance
jkeiffer

Justin · « **Reply #1 on:** March 05, 2008, 01:20:24 pm »

come on no one???

someone on here has to have some trans expirience.

thanks in advance, i am taking it in tonight to have it looked at and accessed tomorrow morning.

Patrick · « **Reply #2 on:** March 05, 2008, 02:17:21 pm »

If it's like an 020 trans, your overdrive is junk. Low on oil maybe? Had a 7A 020 that was jumping out of 5th when I got it, changed the gear oil and ran some Lucas oil treatment in it, ran fine for a lot of years...... YMMV

Justin · « **Reply #3 on:** March 07, 2008, 09:33:50 am »

I think that you are right on the overdrive going out due to low oil after I have done some research. I will be pulling the transmission out this coming week to examine it.

does anyone here have a good source for transmission parts for an 02A or 02J?

Thanks,
Justin

Patrick · « **Reply #4 on:** March 07, 2008, 11:16:19 am »

I'd try topping up the oil first, especially this time of year....... Never know, it might solve you problem, at least for a while.

Justin · « **Reply #5 on:** March 17, 2008, 05:08:47 am »

well I finally got around to pulling the 5th gear cover off this weekend (snow melted away so I could get it on cement to work on).

I drained the oil out of the trans first and did not see any chunks of metal, fluid was a little dirty but not metalic.

pulled the 5th gear cover and to my suprise the two gears for 5th gear look good and they had fluid on them so that was a big sigh of relief.

now I think, but correct me if I am wrong that the 5th gear synchro is bad since it will go into gear with the clutch depressed but pop out even with me holding the shifter hard into the 5th gear posision.

thanks guys,
Justin

jtanguay · « **Reply #6 on:** March 17, 2008, 07:32:27 am »

the synchronizer just makes sure that 5th gear is spinning as fast as the engine so there is no 'crunch' when you put it into gear (eliminates the need for double clutching)

isn't it something else when it keeps popping out? my brother bought a used tranny once for a gmc truck. 1st gear would always pop out, but was never in 1st gear long enough so he'd just hold it there :lol:

Justin · « **Reply #7 on:** March 20, 2008, 04:57:32 am »

well I found the Problem last night, I pulled the fork off of the synchro/selector and the slider pins or what ever you call them that are on the fork that slide inside of the synchro/selector are severely worn, looks like the previous owner was hard on this trans for 5th gear or something, now I need to find those two little things that pivot on the end of the fork and slike inside of the synchro/selector

the Synchro looks to be in great shape and locks into place very well

any ideas where I can get these parts?

thanks
jkeiffer

jtanguay · « **Reply #8 on:** March 20, 2008, 05:00:21 am »

also i believe the 5th gear is the first gear to go when the tranny is low on oil...

not sure where to buy parts for it though

maybe someone with ETKA?

which part on here do you need? i could only find the 02E 6 speed tranny. but i'm kinda tired... maybe later i'll look? what car is your 02J from?

Justin · « **Reply #9 on:** March 20, 2008, 05:43:50 am »

I am not sure if its an 02J or 02A since I cannot find a code stamped into the trans, if you can tell me where to look that would help.

I was told the trans is out of a 98 TDI beetle

the gears and synchro look good and no abnormal wear, and the gears were wet with lube so I didnt get low on oil like I thought, the two parts that I need are not in the picture they slide inside of the part to the left of part number 7 in the picture that you provided.

thanks,
justin

Justin · « **Reply #10 on:** March 20, 2008, 05:59:44 am »

I just called the Dealer and described the part, I am going to go there tomorrow and look at their picture to make sure that they will order the correct part unless I can find a cheaper one tonight. the parts name and part number that he gave me was a shift segment and the PN was
02A 311 585 K with a price of 39.70 each

any ideas?

jtanguay · « **Reply #11 on:** March 20, 2008, 10:18:28 am »

if its a 98 beetle tranny then it is an 02A.

Justin · « **Reply #12 on:** March 20, 2008, 10:52:53 am »

parts are ordered for 23.28 each from 1stvwparts.com should have them next week and be back on the road,

if I could figure out how to post a picture I would post the linkage from ETKA that was sent to me.

Thanks for the help,

Justin

Justin · « **Reply #13 on:** March 31, 2008, 07:02:07 am »

jtanguay,

so I installed the little shift fork pivot thingys and it now goes into 5th but still will not stay in 5th so I think that my snchro is bad, when I put in in 5th with the cover off I cannot turn the gear so the syncro is engaging but under any load on the road it pops out (cover reinstalled) if I need a new syncro ring I should just need part 4 in the illustration for 5th gear correct? does anyone have a part number by chance?

Thanks,
Justin

Justin · « **Reply #14 on:** April 04, 2008, 05:30:33 am »

anyone?