VW T4 Forum - VW T5 Forum banner

1 - 20 of 20 Posts

·
Registered
Joined
·
3,259 Posts
Discussion Starter #1
Right i dont claim to know anything about clutches, gearboxes etc, but from what i have read on here i have a few theories i would like to run by you more knowledgeable folk

Scenario: 1.9D 1995 136k, 1st, 2nd, 3rd, 4th, gears change nicely, up and down, clutch feels smooth, strong and medium height, however on the change up into 5th its makes a slight crunch (hear this and feel it), it goes into gear though no problems. Doesn't do it on change down.

My mates van, 2.4d 1995 180k same thing strangely..

Now ive read a few things here, its seemingly common if we both have thIs issue, im thinking synchro mesh is what i can feel, though how can i fix this?

More gear box oil or change? I dunno how to do this tbh but will search for that.
Or is it the gear box selector bush i see on ebay for a fiver?
Or is it the start of something worse? Let me know what you guys think, thanks! T:
 

·
Registered
Joined
·
3,910 Posts
Does it alter if gear change is "under load" or not?
My guess will also go into the syncro mesh direction.
Drop at least the oil. Take a samle & check for possible metal debries etc I:
Oilchange seldom causes harm when done rightT:
 

·
Registered
Joined
·
3,259 Posts
Discussion Starter #3
Genuine VW Oil has been purchased from TPS at £4.50 a litre, bought 4litres only as thats all they had in stock at my local! Bearing in mind im going to do two vans, so I believe I need about 2.3l per van (dry gearbox is 2.5l but they rarely fully drain)
Im thinking about making up the 0.3 litre with a garbox additive.. Will keep you all posted as to the progress, if it snows tomo i think i may not get it done this weekend :eek:
 

·
Registered
Joined
·
1,458 Posts
Seen 2x 02B gearbox fail when the bearing collapses on the 5th gear, the 5th gears eventually strip.

first signs are usually it popping out of fifth,

gear crunches are normally linked to a worn syncromesh, but I've bever seen that on fifth.

easy to replace without having to take the box off. just drop the oil and take the black end plate off the box.
 

·
Registered
Joined
·
3,259 Posts
Discussion Starter #6
I tend to agree and know deep down in my head its most likely the synco mesh, I will have to research how that can be done.

I have driven my friends van now and his severly grinds going up into fifth, I have to force it in, but when its in, its in! He also complains of it being hard selecting gears going down, but i didnt really find this problem...
 

·
Registered
Joined
·
326 Posts
i think the concensus is that if crunches it will soldier on for a good while yet. If it jumps out of gear then thats when you should worry and get it fixed as it will deteriate quite quick. My 2.4 crunches sometimes. It uses to do it every time but had a chunk missing out of the selector ball. You could not see or feel it as it was the bit at the back but when out it was obvious. That made it only crunch occasionally instead of all the time. Worth the couple of quid T:
 

·
Registered
Joined
·
3,259 Posts
Discussion Starter #9
ok on my friends 2.4 we changed the gear oil and added molyslip additive, and yes, the 5th gear crunch is still there...i reckon its the syncro mesh, it doesn't pop out so i guess he has some time till it does...incidentally he has problems cycling from 3rd or 4th into 2nd, now to me thats the selector bush.

how much is it do the 5th gear mod/change the synchro mesh? Could I do it?! or do i need specialist tools? Thanks
 

·
Registered
Joined
·
12 Posts
Hello I had the same problems mentioned in here and changed the syncro mesh for the 5th gives two day. I took about two hours.

I need twelve angular and hexagonal tools and the gear is right back of the end of the gearboks.

Now: Smoot gear!:)
 

·
Registered
Joined
·
12 Posts
Hello I had the same problems mentioned in here and changed the syncro mesh for the 5th gear to day. I took about to hours.

I need twelve angular and hexagonal tools and the gear is right back of the end of the gearboks.

Now: Smoot gear!:)
 

·
Registered
Joined
·
12 Posts
Hello I had the same problems mentioned in here and changed the syncro mesh for the 5th gear today. I took about to hours.

I need twelve angular and hexagonal tools and the gear is right back of the end of the gearboks.

Now: Smoot gear!:)
 

·
Registered
Joined
·
1,495 Posts
I personally would change the front gear linkages before condemning the 5th gear.
It has a tendency to effect 1st 2nd and 5th. Not always all at the same time depending on where the linkage is worn.
 

·
Registered
Joined
·
3,259 Posts
Discussion Starter #17
deffo a grind feeling on that 5th though, the 2nd gear no grind, just hard to find,, the 5th you can feel something is spinning and when you force it in past the grinding, it hurts..been telling my m8 he needs to look at getting the parts for the 5th gear upgrade, and each grind now will eventually wear the gear down and create more messin his oil which could affect his others gears..,, that sounds about right?
 

·
Registered
Joined
·
1,495 Posts
deffo a grind feeling on that 5th though, the 2nd gear no grind, just hard to find,, the 5th you can feel something is spinning and when you force it in past the grinding, it hurts..been telling my m8 he needs to look at getting the parts for the 5th gear upgrade, and each grind now will eventually wear the gear down and create more messin his oil which could affect his others gears..,, that sounds about right?
A worn linkage will cause a crunch too mate. Your gearbox has a turret on the top which the rods and linkages turn and move up and down to select the gears.
When the linkage is worn the turret is not in the correct position to select gear smoothly. It's basically not lining everything up correctly, causing the crunch.
The second gear being hard to find is the same problem as it is on the opposite pivot of the 5th. Indicating the wear in your balls. I:
 

·
Registered
Joined
·
1 Posts
Hi, i have the same problem exactly, in a mk6 6 speed manual gearbox, only 5th gear crunch and 2nd gear hard to find when cold, 2nd gear is fine when warmed up but 5th gear always has the crunch when shifting up to 5th, but no crunch in 5th gear when shifting down from 6th gear, i can get a complete gearbox and get it changed but if there is a cheaper option (syncro/linkages e.t.c) without removing the gearbox from the car please get in touch as i would like to use your services (07919130896)
 
1 - 20 of 20 Posts
Top