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Discussion Starter #1
Hello all. I'm not sure if anyone can help with this but thought I'd post a fault that has developed and hopefully the cure at a later date.
While slowing at traffic lights yesterday I was unable to shift down into 2nd gear. I could not get into 1st or 2nd while the van was moving. Panicking at the lights, I was then able to select 1st normally when stopped and pull off but on the way home tried to change to 1st and 2nd again and if the van was moving could not shift the stick either up or down into either gear. I managed to get home without using either gear and spent the evening looking on the forum for possible causes. I checked the linkages this morning and found the securing clip on the gate select cable adrift causing it to slide on the selector lever shaft. I then spent a good 30 mins or more selecting gears while on the drive with the engine running with no problems at all. Thinking this was the fault I took it for a drive up and down the street but as soon as I started moving the fault was there. I now suspected the DMF but when tried in reverse on an incline it was fine. I selected first again, pulled off and the van kind of 'bunny hopped' up the street as if dipping and releasing the clutch, this happened when I changed up to 2nd also but stopped when put into 3rd. I have booked into a local garage tomorrow and was wondering if anyone knows if it will be safe for me to drive the 3 miles there safely or if they have any idea of the possible cause.
Forgot to say its a 2005 T5 2.5 TDi T30 AXD (not sure of gearbox) 96bhp with 150k on the clock and a full VW service history.
 

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Discussion Starter #2
Just a quick upadte for those interested.
The 'bunny hop' appears to have been cased by a hose that had come adrift from the turbo. I had noticed a bit of oil in the engine bay while I was looking into the gear change issue and it must have popped off while I was driving it after. I assume it's the one people have said that the retaining lugs wear on.
After replacing the bushes etc that the mechanic said were showing signs of wear, the gear change issue is, however, still there. As he is an ex vw mechanic, he still has friends working for them that are hopefully going to get back to him tomorrow with some ideas on the cause. As there is no unusal noise from either the box or engine it appears the DMF, clutch and box are fine and if all else fails I am a little more at ease about driving it to a vw specialist further away if needed.
I'll keep you posted.
 

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IK had a weird one where it would only go into some gears then pop out of others as you drove along.

It was proper head scratching one till I grabbed the rocker cover and pulled the engine.

I realised that one of the engine mounting bolts had let go and the engine was clunking round in the engine room which was pulling the gear change around.

Rhys
 

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yep check the front engine mount and also the gear selector on the gearbox, there’s a 13mm nut that comes lose on top try that as well :)
 

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I had a problem when driving once, couldn't get out of gear or change untill I switched off the engine, it turned out to be the DMF :eek:
 

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Discussion Starter #7
Thanks guys, gear selector nut is tight, but they have found one front engine mount that needs replacing which is being done tomorrow. DMF seems to have been ruled out as no problem reversing on and incline and no unusal noises or anything. Still changes up gears fine but not down into 1st or 2nd when decelerating, but does when you come to a stop. Wait and see if the mount makes any difference tomorrow.
 

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Discussion Starter #8
Just an update on this post I started so you all know how it ended.
Changong the engine mount made no difference to the fault so I took it to a local, highly recommended, independant VW/Audi specialist.
After a few days of trying a few things I was contacted to say that the problem was just with 2nd gear and that box was going to have to come out for a rebuild and possibly have the clutch and DMF replaced. This was the week before Christmas, but I was told that all going well, it could be ready before New Year. Then....nothing. I finally contacted them at the end of the first week of the new year to be told the box was back from the re-builder but not in. A week later I called again to be told it was in but not right, so was going back to the rebuilders. Another week and when I called the box was back in but no longer had first or second gear at all and had to come out again.
I finally picked the van up 2 days ago, 7 WEEKS after dropping it off, and with a £2,000 repair bill.
Although now running perfectly and driving like new, the whole experience was a nightmare.
In all, I had a new clutch, new DMF and the gearbox rebuilt (3 times before it was right).
The clutch and DMF removed from the van were the originals (although it has covered 150k miles, and I confirmed ths with the original owner) and the DMF starting to fail had caused damage in the box affecting the second gear.
I have noticed other posts on here with people with the same fault and hope this is of some help to them.
 
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