question about transmision installation - TDI Engine -General Info - VWDiesel.net The IDI, TDI, and mTDI source.

• question about transmision installation by theocrytus on 31 Jan, 2007 22:42
• i had a guy install a " 5 -speed " manual tranny in my car rebuilt. problem is it does not seem to have a 5th gear.. could this happen due to a installation error.?
• #1 by RabbitGTDguy on 01 Feb, 2007 07:12
• Well...I think that depends. First off....what car are we talking here? A factory TDI in MKIII/IV, passat, etc. or is this a swapped car with a 020 trans in it possibly.
  
  If its MKIII/IV , passat, etc. It'd be hard to fudge cableshift up that much on the install unless he messed with the shifter cable adjustments, etc. and really fouled them up. I've had quite a bit of experience with cable shift (converted two cars from auto to manual, one my 'rado I used to have) but have found it hard to "lose" 5th gear completely even with a messed up linkage alignment at the shifter, etc. Though, I suppose that doesn't mean its impossible. They can be really sloppy feeling sometimes, etc. But if your hitting all the other gears without issue...then I'd question things.
  
  If its an 020 trans we are talking about from an older car in a swapped car...that could be a different story. You could lose 5th, but if you did you'd also have issues with 1st and reverse as well. Was this car a 4 speed converted to a 5 speed? If all the 5 speed linkage arms at the tranny weren't used...it could be a problem. Though I haven't had it happen personally in a 4-5speed swap with 020's, I've heard of people having issues when they use the 4 speed style gate (mounted at shifter base, under car) on early MK1's with the 5 speed swap and loosing 5th there...
  
  A little more info on the car would be good. But there is something to start with...sounds like it could really need to be aligned, etc. (shifter and cable adjustment for 02a/j style cable shift trannies) or (adjustment at shifter for 020 trannies, possibly need to look at shifting linkage at tranny as well.)
  
  Joe
• #2 by theocrytus on 01 Feb, 2007 07:58
• My car is a 1986 1.6l turbo diesel jetta and was a 5-speed when i took it too him. there is a little bit of in issue with reverse and 1st. if i am not careful, it is way too easy to get into reverse... at least compared to before transmision swap.
  
  as for 020 i am not sure about those numbers.... if maybe you could elaborate on that i woulde appreciate it.
• #3 by RabbitGTDguy on 01 Feb, 2007 10:40
• well...for one then, your an IDI (indirect injection) turbo diesel engine, not TDI (turbo direct injection) setup and would want to be in the IDI forums for any engine help, etc. you might need...though, many of us have had experience and worked with both...but for organizational purposes , there is a IDI specific forum for you.
  
  As for your transmission problem... your car would utilize an 020 transmission. Which is a cable clutch and mechanical linkage operation. TDI's received the next style of transmission that VW came out with in the introduction of the B3 passat and Corrado in 1989 which is the cable shift 02a and 02j versions. These transmission tend to be more "beefy" in their durability and are "wet" clutch setups...they use hydraulics for clutch operation (though there is a transporter various that does have a cable actuated clutch setup) and the gear shifting itself is operated by "shift cables" that run from the shifter to the transmission shift tower vs. using the mechanical linkage like the 020's do.
  
  In your case it sounds like the linkage itself may be miss aligned. If its super easy to get reverse, then its possible things are tweaked "to the left" and you need to be able to realign the linkage, etc. to get the proper alignment. Bentley gives accurate descriptions in how to go about this, etc. Its not too difficult.
  
  Don't know if that clears it up...
  
  Joe
• #4 by theocrytus on 01 Feb, 2007 17:38
• Thank you for your help Joe. It is definetly a linkage problem. most of it seems to be fixed now, but I had a different person take a look at it and he tells me that my shifter is also " worn out".
  
  And also thank-you for telling me that my car is IDI and not a TDI I have wondered that for a while now.
  
  Chris
• #5 by RabbitGTDguy on 01 Feb, 2007 18:37
• Chris,
  
  No problem... make sure you question is someone says your "shifter is worn out", etc. etc. Most MKII's can have many many many miles on them without the shifters being "worn out" its an improved design, especially over the MK1 setup in which the ball at the bottom of the shifter does "wear out" and eventually crack, etc. resulting in more slop in the shifter... but there are easy to install rebuild kits for these items, etc. Generally what wears out is the linkage and the associated bushings on the transmission linkage itself, the "ball and sock" hemi joint linkages. They are plastic on the ends and the bushings are plastic as well and they ovalize over time and the linkage ends actually crack. Making things sloppy. Your situation sounds like it could use a nice rebuild (linkage rebuild kit may cost you $8 for the bushings, 5-10 for the linkage pieces, etc. 20.00 on a shifter rebuild kit, etc...) but really the issue of no 5 sounds like a major alignment issue in the linkage somewhere. Just my opinion. If the installer took your shifter loose at all, etc. its def. out of alignment and the MKII used a really slick alignment tool to get things back to spec....well worth the $12 investment to have for you and any buddies with MKII, it may even work with the MKIII as well...can't remember.
  Here is a complete MKII shifter/linkage rebuild kit that includes the tool...
  
  here is the link to where you can buy it... $110.00 takes care of everything and you get the tool as well. All OEM parts...
  http://www.parts4vws.com/catalog/product_detail.asp?PartNumber=A2798211
  
  There are really nice kits out there to rebuild your linkage and put almost lifetime bushings in as well. The MissingLinkz kit that Roger Brown makes and sell comes to mind....AWESOME stuff... adjustable heim joins, teflon bushings, etc. Good stuff...more expensive, but worth the investment at close to 100.00 for a complete kit (linkage and bushings) . If I stay 020 for my trans selection, I'll be adding this to the bunch.
  Here is a link to Roger's site, etc. for MissingLinkz upgrade... good stuff. Say hi from me if you end up buying one Alot of good information on his site though regarding operation, improvements, and he has a bunch of options...
  http://www.4crawler.com/Diesel/ForSale/ShiftLinkage.shtml#Introduction
  Here is his 100.00 linkage upgrade kit...
  
  
  
  Hope it helps...
  
  Joe
• #6 by theocrytus on 02 Feb, 2007 20:23
• Joe,
  
  thank-you for all of your help. I really appreciate it.
  
  Chris