Author Topic: Gearbox Issues....Any advice? (Read 11910 times)

bvolks73 · « **Reply #15 on:** October 29, 2006, 06:55:23 am »

Those old transmissions are definitely tough. At around 590,000 kms I couldn't keep gear oil in mine anymore because there was so much play in the differential that you couldn't keep seals in it. The last time i tried to put oil in it through the speedometer hole it was running out almost as fast as I could pour it in. To keep it going until I could find another transmission I'd fill it with lithium (I believe) grease from a grease gun. It would thin out and push out the by seals eventually but not as fast as the gear oil. The transmission was never quieter. Lol. It made it shift some hard though until it got warmed up since this was in the middle of our canadian winter. The tranny I ended up putting in it had been run dry of gear oil once and driven that way for a while and had a whine in 5th. The guy I got it from said it had been that way for a couple years and his mechanic had told him to turn the radio up and forget it. I've put over 120,000 kms on it since with no trouble at all. Not bad for a freebie.

TomB · « **Reply #16 on:** October 29, 2006, 11:30:25 am »

hillshy thanks for the offer anyway

I did about 350 miles over the weekend, and I can now tell exactly when it's getting unhappy in 5th and change down as the whine gets louder... Leave it for half an hour then change up again. Repeat until journey is completed!
I'm going prepare the credit card for a beating and get a recon box I think. Not the cheapest option, but more reliable that eBay, and comes with a years guarantee.
Should probably get the MOT that's due next week out of the way first though...
Thanks again for all your help,
Tom

jtanguay · « **Reply #17 on:** October 29, 2006, 02:19:49 pm »

make sure you get a box with long gear ratio's to offset the cost of the transmission with lower fuel consumption!

TomB · « **Reply #18 on:** October 30, 2006, 11:37:09 am »

burn_your_money, sorry I missed your question the first time around. The info on the gearing is on BrokeVW's site (I hope he doesn't mind me posting the link below for info).
Cheers,
Tom

http://www.brokevw.com/020ratios.html

TomB · « **Reply #19 on:** December 29, 2006, 05:05:02 am »

Well the mileage continues to mount, and the hunt is ongoing for a replacement box, which brings me to this question:
The code 4T gearbox was used on SB Engined GTDs, but also on 1.6 petrol Jettas and Golfs. Does anyone know if the ratios change between codes, or would all code 4T boxes have the same cogs ratios etc?
Cheers,
Tom

smutts · « **Reply #20 on:** December 29, 2006, 02:38:37 pm »

When the stupid diff pin rivet committed suicide, smashing six BIG holes in the casing, I had a chance to find out.
The petrol 4T gearbox fits my SB engined GTD just fine. Ratios were just the same.
Git of a job though, as there is precisely 5mm less room than what you need to get the job done.
Thats life these days. I used to change the clutch on my 1977 datsun cherry in a leisurely 45 minutes. Such is progress. :roll:

TomB · « **Reply #21 on:** December 30, 2006, 10:52:37 am »

:mrgreen: you sir are a scholar & a gentleman. That's just saved me a ton of money and worry, as there are 3 code 4T boxes in my local scrapyard all currently attached to petrol Golfs. Time to find the one with the lowest mileage....
Worrying about fitting it is something to do in the new year...

Thanks again,
Tom

smutts · « **Reply #22 on:** January 05, 2007, 08:46:57 am »

Not that I was boasting of my skills ref Cherry, it was just SO EASY. Obviously with all the stealers starving to death, SOMETHING MUST BE DONE.

The VW gearbox was a 3 day swearfest due to the engine bay being precisely 5mm too small in any desired direction, but after looking in the engine bay of a new Fud Focus turbodiesel I hired on holiday, I didn't know how lucky I was. Put a piece of cheese in the middle of that lot, release a million mice, all the mice will starve. Dealers must be giggling though. £50p.h. + vat.

Pity vw didn't look at the G.M. Vauxhall Opel gearbox, as with the o20 pushrod setup they were nearly there, pity.

If for whatever reason you've got to gut one of these gearboxes, replace the wretched crownwheel rivets with proper stress graded bolt kit & captive tabs. Allegedly VW sell a kit to do this. Look up a previous post I did, as it will give the relavent Bently page, don't ask how I know. :roll:

If the cooling system has been neglected, whilst you have the gearbox off, notice how there is a core plug hidden by the bellhousing waiting to rot and piss coolant out once you've put the gearbox back on. Hmm.

The Haynes manuals, and most others, seem to give the wrong torque settings for the "clutch" to crankshaft bolts, mine were shouldered, and if memory serves, I used the 55ftlb figure + locktite. Apparently it's supposed to be 70something or other ftlb. Oh Bum.

Good Luck

c_wilso · « **Reply #23 on:** January 09, 2007, 05:55:03 am »

Yeh my Diff has also went just before chritmas blowing holes in my box. Looking for a 4T but nobody seems to have one how did you manage to have 3 in your local yard?? have got other boxes which VAG tell me will fit but obviously ratios are different so ideally looking for a 4T

slimc · « **Reply #24 on:** January 09, 2007, 11:38:19 am »

I have been having problems engaging gears and 5th gear popping out a friend suggested it could be the gear linkage needs repairing for about £10 from GSF and how to do it from this site

newbielink:http://www.forum.golfgti.co.uk/index.php?topic=33100.0 [nonactive]

I will let you know how it goes

slimc

burn_your_money · « **Reply #25 on:** January 10, 2007, 01:24:39 am »

Very nice write-up slimc thanks

TomB · « **Reply #26 on:** January 15, 2007, 09:50:21 am »

c_wilso credit to the man in my VAG parts store (not a main stealer but an independent who pointed out that the 4T boxes were fitted to most of the 1.6 petrol Jettas & Golfs. I was in the scrapper looking for bits and just thought I'd check & got lucky!
Fate has forced my hand, and I've now got a replacement box in the boot awaiting an install. After 3000 miles 5th cog finally grenaded about 100 miles from home yesterday. I'm glad VAG boxes are tough, as I just dropped it to 4th & continued on my way, ignoring the sound of gargling spanners from the gearbox as the component parts of 5th beat a tattoo against the bottom of the box...

TomB · « **Reply #27 on:** January 20, 2007, 01:49:39 pm »

A ha ha ha! Just got the replacement box in along with a new clutch and seals, and it feels like a totally different vehicle.
The clutch is feather light, the shift seems smooth and it seems to pull harder. I still haven't taken it on a long run, but I'm going to keep my fingers crossed....
Total cost was £75 for the box & £250 notes to the garage including £100 of new parts (clutch & seals). Considering the cost of a recon. box would be £450 + VAT + fitting, that doesn't seem so bad... :-)
Cheers for all your help gents, and btw, in case anyone else has a similar problem, then once the damage has first been done, mine lasted exactly 3000 miles before punching a large hole in the casing... :-)