012 DUK Transmission Speedometer Gear Malfunction

[iMax]

I have a DUK manual transmission I swapped into this Passat maybe 5 years ago. Not sure if this a 01E or an 012 transmission but the manuals both seem to match when I look at them minus the all-wheel drive parts.

Anyway... the speedometer stopped working and changing the VSS did nothing. I eventually ordered a new speedometer gear and opened the driver side flange. The original speedometer gear had cracked in half and was just floating around the differential shaft. I replaced this and made sure the new speedometer gear fit into the little keyway. Sealed the transmission back up but still no speed readings but it did read going in reverse.

I made a visual inspection today through the little VSS hole (very difficult mind you) and the speedometer gear isn't moving again. Moved it a little with a pick and the gear moves intermittently but still fails while under speed. My thinking is the centrifugal force is pushing the speedometer gear out of the keyway. Does any of this make sense to someone?

I seated the seal with 2062 Drift but perhaps the seal is not deep enough to secure the speedometer gear on the differential?

I plan on ordering more fluid and another seal to make, yet another, look inside on the driver's side flange and try to understand why this is happening to me. Hoping somebody has a past experience to give a better diagnosis.

 

[caffeine]

If you can't figure it out, another alternative is to program the cluster to get the speed signal from the ABS module, and just delete the sensor altogether.

 

[iMax]

I've heard of that but no clue how that works or even the process to make that happen. Guess google it is.

 

[yadic]

I have a DUK manual transmission I swapped into this Passat maybe 5 years ago. Not sure if this a 01E or an 012 transmission but the manuals both seem to match when I look at them minus the all-wheel drive parts.

Anyway... the speedometer stopped working and changing the VSS did nothing. I eventually ordered a new speedometer gear and opened the driver side flange. The original speedometer gear had cracked in half and was just floating around the differential shaft. I replaced this and made sure the new speedometer gear fit into the little keyway. Sealed the transmission back up but still no speed readings but it did read going in reverse.

I made a visual inspection today through the little VSS hole (very difficult mind you) and the speedometer gear isn't moving again. Moved it a little with a pick and the gear moves intermittently but still fails while under speed. My thinking is the centrifugal force is pushing the speedometer gear out of the keyway. Does any of this make sense to someone?

I seated the seal with 2062 Drift but perhaps the seal is not deep enough to secure the speedometer gear on the differential?
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I plan on ordering more fluid and another seal to make, yet another, look inside on the driver's side flange and try to understand why this is happening to me. Hoping somebody has a past experience to give a better diagnosis.

f the speedometer gear isn’t moving, it could indeed be related to the seating of the seal or how the gear is seated in the keyway. If the gear is floating out due to centrifugal force, ensure that the new seal is properly seated and provides enough retention. Additionally, inspect the gear for any signs of wear or damage that could affect its ability to engage properly. It might also be worth checking the VSS wiring and connections for any issues. Good luck!

 

[iMax]

The manual called for like 5.5 mm of seating the seal. I didn't measure just went until the drift bottomed out. Might have to go back and be sure. The wiring I already did check for continuity and then spun a magnet on a drill next to the sensor and the speedometer reads. So the wiring/fuse/sensor is all good. Still waiting for the stuff to ship before I can open that axle back up. Hopefully soon I can report back soon.