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Tdi Gearbox (again)


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Hi guys, so first a bit of history.

I brought the car 1 year ago with 142k and within a few days realised that there was a gear change problem.

changing from 2nd to 3rd too quickly resulted in a crunch which was worse when cold. I changed the gearbox oil and adjusted the linkages but no joy.

No bother I thought, I will get another gearbox, swap them out and change the clutch for good measure, safe in the knowledge that the car will go on for years to come.

So I saved my pennies and brought a second hand gearbox, fitted it with a new clutch and would you believe it that is still crunches going from 2nd to 3rd when cold!!

I find it hard to believe that I have managed to pick another gearbox with exactly the same problem.

My thoughts are that surely there must be something worn or baggy between the shifter and the linkage???

i am really disheartened as I love the car and want to keep it forever lol but she will have to be traded in If I can't fix this ?

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Syncros fail on 3rd gear, mine had the problem of not going into 3rd on the way down the gearbox but it was fine going up. The gearbox was rebuilt by our well respected local gearbox specialist, but the price including re fitting circa £500 was considerable and this problem renders many TDI repairs uneconomic

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  • 4 months later...

Do you think that sloppy/worn linkages could cause this problem?

Reason for asking is that my 2nd Tdi has a good gearbox and the difference between the sloppiness of the gearstick is really noticeable.

The gearstick on the crunchy car has tons of sideways play when in gear, where as the good car doesn't have any and feels really tight.

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So I have been doing a bit of investigating today and have compared the two linkages in both cars.

hopefully the videos will load...

The first thing I noticed is that they are both different. The first video shows the crunchy black car. The second the silver.

The silver car has the linkages attach with a ball and socket kind of arrangement where as the black car has a pin and clip.

The videos show the cars in 3rd gear with me wiggling the gearstick from left to right. You can clearly see the play and flex in the linkage on the black car.

Which linkage arrangement is correct

A7E612DA-D918-4490-9689-A01E07ACFFDE.MOV

36C6EB80-64FD-4EE7-B144-4352524C6464.MOV

EDIT: Not sure if the links work....will load em onto YouTube and post in a moment 

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On the sloppy crunchy one you can see the metal counter weight bit with the nut holding it (your last pic) has play on the shaft and is moving about, on the other one it has no play and the selector moves up and down cleanly, check the nut tightness, if tight remove it and put some pvc tape or similar on the spline and reassemble and see if it makes a difference with no slop.

Edited by Sausage
a word
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It's worth a try eh.

I think I will first swap the counter weight and linkage clips from the good to the bad car and see if that helps.

The sloppiness is exactly the same on the new gearbox as the old one. At least then I will know for sure without spending out out on parts

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I come here bearing great news ???

Swapped the counter weight and linkage catches over today and it has completely fixed the crunchy 2-3rd gear shift.

I have driven about 10 miles and completely hammered the gearbox and I just can't get it to crunch at all.

To say I'm stoked is an understatement. This gearbox issue has been a pita ever since I brought the car and has really darkened the Tdi experience. I'm in love with it again ???

I always had a deep down feeling that this second gearbox couldn't have the same problem as the one I chucked in the skip 9 months ago (which was probably also fine)

Buying the silver Tdi, and having something to compare it against confirmed my suspicions.

Happy days......now I have two mint Tdi to play with ???

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