2002 5 speed shift problem (grinding)

[Black Lab]

Good day all,

I have a 2002 TDI 5 speed manual jetta. In the last month or so the car has developed shift grinding problem between 1st and and 2nd upshift and 2nd 3rd upshift. I can heel/toe from 3rd to 2nd with out an issue when coenering around town. Now here is the kicker, it only dose it after the transmission is warmed up. The first 30 min or so of my drive to and from work is business as usual, but after the trany warms up, I start to get this grinding problem. I can reduce or eliminate the grind by slightly tweeking the way I shift, but its annoying. I don't drive it hard, most of my shifts are between 2500-3000 RPM.

The car has only 240,000km (150,000mi)
The Luk clutch kit is only a year old, 16,000km on it and I replaced the leaver and pivot at the same time
I have bled the slave cylinder, no change
I have adjusted the shift cables, no change

I have ordered some Amsoil lube to replace the fluid in the tranny but it has no arrived yet.

Any thoughts comments are much appreciated.

Cheers!

 

[UhOh]

When was the fluid last changed? And with what?

What are your ambient air temps when you start out?

Did you adjust your linkage?

Best trans fluids (from my research):

1*) AC Delco Synchromesh with Friction Modifiers (from GM dealer or on-line);
2) Pennszoil Synchromesh (available almost anywhere);
3) VAG G052 or G060 (G052 was superseded by G060, which has also been superseded by G070; you can still find G060 around, and G052 might be more difficult; G070 doesn't have good reviews in these transmission).

* Running in a warmer climate then I'd go with one of the others.

I am running the AC Delco fluid in my two 5spds. Seems that shifting is starting to wane a bit, and that perhaps I need to do another fluid change. Running with the original fluid it might take a flush to make sure it all gets out: not sure, though, how sensitive the transmissions are to having some residual of older stuff.

I've got the Diesel Geek short shifters in the two 5spds. These shifters tend to be a bit more demanding, resulting in slightly notchier shifting. Second gear just seems to be generally kind of cranky: even my 6spd, which is a great transmission, is a bit sensitive with 2nd gear shifts. I do not have any issues shifting to 3rd gear (upshift or down****).

 

[dirtride]

Good day all,
I have a 2002 TDI 5 speed manual jetta. In the last month or so the car has developed shift grinding problem between 1st and and 2nd upshift and 2nd 3rd upshift. I can heel/toe from 3rd to 2nd with out an issue when coenering around town. Now here is the kicker, it only dose it after the transmission is warmed up. The first 30 min or so of my drive to and from work is business as usual, but after the trany warms up, I start to get this grinding problem. I can reduce or eliminate the grind by slightly tweeking the way I shift, but its annoying. I don't drive it hard, most of my shifts are between 2500-3000 RPM.
The car has only 240,000km (150,000mi)
The Luk clutch kit is only a year old, 16,000km on it and I replaced the leaver and pivot at the same time
I have bled the slave cylinder, no change
I have adjusted the shift cables, no change
I have ordered some Amsoil lube to replace the fluid in the tranny but it has no arrived yet.
Any thoughts comments are much appreciated.
Cheers!

I started to get this last summer when it's over 95F outside, after I drive the car on the highway at speed for over 25 miles. Was running Red Line 85W-90 gear oil, as recommended by them for VW 5 speed manual.
Just recently switched to the Pennzoil product. Already noticed a difference in shifting, in a positive way. True test will be in summer time when it gets hot outside.
When you drain you're old oil, take note. Does it look like gold dust is suspended in it? Sometimes I suspect that removing the DMF to SMF causes excessive synchro wear in the 02J. (but also have read here that SMF will not cause synchro wear)

 

[Dorsal]

FWIW I had a grind from 2nd to 3rd with my 02m, used The Penzoil syncromesh and it went away. 35,000 miles ago.

 

[Black Lab]

Update.....

I replaced the tranny fluid with Amsoil 75w90 (GL5) long life gear oil that I bought form a buddy of mine that's an Amsoil dealer. The shifting changed considerably, I noticed the it was a little notchy on a cool morning about 0 deg. C (32F) but the grinding after the tranny heated up went away completely.

Then I did some more research and realized he had given me the wrong fluid. The fluid I should have used is the Amsoil Manual Transmission Fluid (GL4). I guess the GL5 fluid is not suppose to be good for the softer metals in our gear boxes. So I got two quarts of Amsoil MTF and changed it again. I noticed it's quite a bit different in viscosity as I was pouring it (much thinner). So far so good with the new fluid. The best of both worlds I think, not as notchy when cold and no grinding when the tranny warms up. But the real test will be in the summer.......

 

[ConvergenceFreak]

I did a manual swap with an 02J out of a donor with 240k miles on it, this donor car had thrown a rod and when we opened it up it had a race clutch installed. I have no idea if that trans was original to the car or was part of the upgrades, it was a DQY btw. We filled it with Synchomesh found at Walmart and there was a grind from 2-3 upshift. Switched to G052 found at the dealer 1.5 years ago and it has gone away entirely 20k miles ago = Happy!

 

[Matt-98AHU]

These transmissions really don't seem to like GL5 oils at all. Heck, even the Red Line MT90 and MTL don't seem to be all that great in them either in my experience. I've also had more than a few complaints after customers changed their gear oil with Lubro-Moly 75w90.

OEM Gear oil works very well to take care of grinds. For extra crunchy transmissions, you can make a difference by mixing OE gear oil with some Red Line Shockproof Lightweight or Super lightweight. It's an odd, opaque color, but they make for a very slick shifting transmission with no grinding if the synchros have not been too damaged.

 

[scottw99]

I'm up in Canada and just refilled my O2J with Fuchs 75w FE (I think it's a 75w80) which seems to be right in between the stock fluid (a bit thin) and recommended 75w90 which I think is a bit thick (referring to a viscosity post on bob the oil guy I found) for Canada, and it's also GL4.

I found that the 75w90 synthetic the previous owner put in there to be a bit crunchy and sluggish in cold mornings but was fine after that. I'll see how the Fuchs is for cold mornings and also long drives when the temps get up.

 

[jettawreck]

Update.....

I replaced the tranny fluid with Amsoil 75w90 (GL5) long life gear oil that I bought form a buddy of mine that's an Amsoil dealer. The shifting changed considerably, I noticed the it was a little notchy on a cool morning about 0 deg. C (32F) but the grinding after the tranny heated up went away completely.

Then I did some more research and realized he had given me the wrong fluid. The fluid I should have used is the Amsoil Manual Transmission Fluid (GL4). I guess the GL5 fluid is not suppose to be good for the softer metals in our gear boxes. So I got two quarts of Amsoil MTF and changed it again. I noticed it's quite a bit different in viscosity as I was pouring it (much thinner). So far so good with the new fluid. The best of both worlds I think, not as notchy when cold and no grinding when the tranny warms up. But the real test will be in the summer.......

Yep, the "proper" fluid from Amsoil is the 75w-90 MTG (Manual Transmission/Gear) GL-4 oil. I've used it for a long time since the first fluid change and it's always worked great in even very cold temps.

 

[PakProtector]

Just did a 17-050 clutch replacement, and refilled with G 052 171 A, the more expensive of the two G 052's ). When warm it will grind on upshift 1-2 and 2-3. That stuff is coming out, and Redline MT90 is going in. There should be a wee bit of the MT90 dilution with the remaining G 052 that won't come out.

Will update when the MT90 arrives and I get it in.
cheers,
Douglas

 

[jettawreck]

Just did a 17-050 clutch replacement, and refilled with G 052 171 A, the more expensive of the two G 052's ). When warm it will grind on upshift 1-2 and 2-3. That stuff is coming out, and Redline MT90 is going in. There should be a wee bit of the MT90 dilution with the remaining G 052 that won't come out.

Will update when the MT90 arrives and I get it in.
cheers,
Douglas

Personally from everything I've read, I would skip the Redline and go try Syncromesh. .02

 

[dirtride]

I'm liking my "mesh" over the Redline so far. Summer heat will be the true test.

 

[sisyphus]

I ran Royal Purple for a few months but the shifting was awful and ended up going to Synchromesh. Never looked back.