Stiff 1st Gear

[Dru1.4]

Hi all, 

I have a 1.4s manual.

Recently I have been quite a stiff 1st gear. It doesn’t seem to want to get into 1st when stationary. It can get into first when moving but it’s still quite hard. There’s no grinding.

sometimes it even struggles to get into second. It selects 1st fine when the car is off but when it’s on it doesn’t like it.

I’ve read it could be a synchro or worn pinion from people with similar problems, does anything stick out to you guys?

I’ve read this:

has anyone on here done this before and have any tips or pictures of what they’ve done?

im trying to get this done myself before I pop it down to f1 auto and get bankrupted for a gearbox rebuild.

Anything would be appreciated,

Thanks, Dru!

Edited December 13, 2024 by Dru1.4
Extra info

[mk2]

Sounds like your clutch might not be fully disengaging... Your syncro rings will be getting a good beating. Lots of metal floating in the oil. Once sorted, flush the box.

Could be a dodgy pedal box? What's the clutch pedal doing?

[mk2]

Scratch that. 1.4's have a different setup for the clutch- not the pedal box.

[Dru1.4]

Was just driving it, shifted from 2nd to 3rd and something snapped. The gearstick is now very loose but for some reason it’s slightly solved the getting into 1st issue. It still doesn’t like it a bit but it’s going into first?

Theres absolutely 0 tension in the gear stick but it still shifts and I’m able to change gears.

I’ve attached pictures of under the gaiter.

as for the clutch it feels okay, there’s a build up of tension when I press the clutch in and then after a certain point that tension drops a bit and then it fully presses in.  It was like that on my old 1.0E not sure if it’s normal though.

hope it something simple ahaha

[Dru1.4]

So the car then got stuck in 2nd and the stick was no completely loose and not being able to move side to side.
 

Upon checking the linkage , one of the cables has snapped off the linkage shown in the below picture.

Whilst I source a linkage, am I able to just bolt the linkage back to the cable so it can shift?

[mk2]

Yeah, that'd would work fine if you can't just snap it back on? Stick might be a bit sloppy, but should keep working for years like that.

 

[Dru1.4]

Perfect, I’ll try that. Many thanks!

[lupo 1.7sdi]

You can find the screw and nut codes below. I think you can also use a normal M8x30 screw (that screw has a chamfer that doesn't allow it to be turned). When you install the cable, the two parts must overlap exactly so that you don't have problems changing gears (that cable is responsible for transmitting the forward and backward movement of the gear shifter).
You can see that the fuse on the other cable is not in very good condition and it is possible that it will come out, below you have its code.

http://www.catcar.info/audivw/?lang=en&l=c3RzPT17IjEwIjoiQnJhbmQiLCIyMCI6IlZXIiwiNDAiOiJMdXBvIFwvIEx1cG8gM0wgVERJIEV1cm9wZSIsIjUwIjoiMjAwMiIsIjYwIjoiUGVkYWxzIiwiNzAiOiI3MTEzMCJ9fHxzdD09NzB8fGJyYW5kPT12d3x8bWFya2V0PT1SRFd8fG1kbD09TFUgICB8fEVwaXM9PTIzMXx8RWluc2F0ej09MjAwMnx8TWFpbkdyb3VwPT03fHxCaWxkdGFmZWw9PTcxMTMwfHxHcmFmaWs9PTA3MTEzMDE1OA%3D%3D

 

https://www.oemvwshop.com/n-90530101-split-pin-1-7x13-5-p344145/

[Dru1.4]

That’s so helpful, thank you so much for those part diagrams!

I’ve done exactly what you’ve said and put an M8x30mm nut and bolt through the cable as shown below. It’s not the prettiest, I know 

It now shifts through all gears but the stick is a bit off from what I remembered. 

1st gear is quite far forward on the shift pattern whilst 2nd is quite far back on the pattern. Neutral also sits higher on the pattern.

Im assuming I just need to do a better job of aligning the linkage and cable end?

Many thanks for the links to that fuse too. It hadn’t occurred to me, you’ve saved me a lot of trouble!

Edited December 22, 2024 by Dru1.4
Typo

[Rich]

Check that the aluminium bracket bolted to the box hasn't snapped. 

They love to do that. 

Also, the rubber centre of the cable sometimes like to pop out, yours looks good. 

[lupo 1.7sdi]

There is an adjustment procedure, but I don't know where you'll find that "3192 Gear stick jig". I've never seen one myself.
Below you have the adjustment procedure and a simplified diagram of the selector mechanism where you can see what is done for the left-right and forward-backward movement

Adjusting gear change mechanism.pdf

[Dru1.4]

Thanks for the advice and letting me know Rich! I’ve just had a check and that bracket seems to be okay (for now). I’ll keep an eye on it though.

Cheers, I’ve had a read through that gear adjustment manual and yea I have no clue where I’d even find that jig, most likely obsolete with most dealers/garages?

For now I’ll probably try popping it in neutral and adjusting the cable until it feels right, best I’ve got is trial and error without that jig ahaha. 

For some reason it doesn’t allow me to open that pdf, I’ve found the manual here (page 54) if anyone else can’t see it. I wonder if it’s different for the arosa, I’ve read that others have done it without the jig so I’ll probably look into that too.

https://cardiagn.com/1999-06-vw-lupo-wiring-5-speed-manual-gearbox-085/

Thanks for your help! I appreciate it

[lupo 1.7sdi]

15 hours ago, Dru1.4 said:

For some reason it doesn’t allow me to open that pdf

You need to install a PDF Reader

I can't see the manual you posted (it says it's for US visitors only). So I took some printscreens for you after the procedure.

 

[Dru1.4]

Thank you for the screenshots 🙏 I’ll know now for next time

The M8x30mm bolt I put in a few days ago came loose which was causing the floppy stick. I went to tighten it and it was okay…for a while.

The cable end then decided it didn’t want to be a cable end anymore and snapped off as shown below. I it was going to happen at some point I guess.

In the meantime whilst I sourced a new cable (6N0 711 265 b), I moved the linkage into 2nd so I could at least go shopping.

The loop didn’t like this and decided to blow the thermostat housing off the coolant regulator housing. One of the threads in the coolant regulator housing failed and so it then leaked out all coolant from the thermostat

I hadn’t noticed until I saw the forbidden steam from the bonnet. I’m not sure how many gaskets I’ve blown but there’s a huge leak from right side of engine along with the thermostat leak on the left.

I’ve been able to source a replacement regulator housing (032121111BB) but I’m not sure if it’s worth going down the money pit of replacing gaskets

 

[Rich]

I have two whole selectors hanging on the wall.

[Dru1.4]

You sound very resourceful Rich, I’m still thinking about what I should do with it. I want to keep it and repair it but it would have to be in the future. I also don’t want it to sit on my drive when it could go to someone else…