2004 TDI 5 speed manual 1-2 and 3-2 shift improvement

[docta96]

At about 180,000 miles, my 2004 TDI PD had developed a gradually worsening second gear graunching noise when upshifting and downshifting the manual 5-speed transmission. This increased over the next 10-15 thousand miles. Quiet shifts were possible only by double clutching or very deliberate upshifting. The concensus diagnosis was second gear synchronizer wear. At the 200,000 mile service this week, I changed the transaxle lubricant to GM Synchromesh fluid (Pennzoil carries it with the GM part number on the label).
I am happy to say that things are better than normal with no more 1-2 or 3-2 shift noises and smoother shifting in all gears. I am now on my way to 300,000 with everything functioning as new. The effect was almost immediate.
After changing the fluid, I drove the car about 100 miles and changed the fluid again to get more of the old stuff out, using two quarts each time. I had previously replaced the transaxle fluid at the 100,000 mile service with VW fluid.
I have no idea if this will work for anyone else, but it did for me.

 

[naturist]

Interesting. It should be noted that the second gear syncro gets the worst wear of all, since it gets traffic in both directions so much.

 

[Dimitri16V]

My 01 is on Syncromesh and it shifts much better than it did with the stock fluid

 

[docta96]

Shift improvement

I amabout 4,000 miles into the change over to GM Synchromesh Fluid in my 2004 TDI PD. Not only is the graunchy shifting in into second gear cured, but the shifting in all gears is smoother and more effortless than new......I am now at 205,000+ miles and the car drives better than it did when new. It seems that the GM stuff really did work for me.

 

[Ol'Rattler]

Awesome. That is what we call imperial data. Data found by trial and error. Keep us advised.......................

 

[docta96]

Anecdotal data

Anecdotal data is simply research using an N of 1........

 

[Lug_Nut]

As long as N = me, I don't care about any additional data points.

I drained my O1M of what I suspect was still factory fill oil this weekend (225k miles on the trans). I then filled it with Valvoline synthetic. My need to double clutch to obtain first when at a standstill, and to occasionally have to do the same for 5th while moving, are gone.

 

[Riflesmith]

Changed transmission lube when installing .658 5th gear. Used LubroMoly 75W-90 GL-5. Label indicated yellow metal compatibility and good synchronizer properties. 4K miles later and I couldn't be happier with the shift quality in every gear and situation. Time will tell how well it will shift in cold weather.

 

[zoompastu]

I've heard good things about running the GM fluid in the Mazda forums when I had my Mazdaspeed Protege, although I have never used it. Royal Purple makes a syncromesh fluid called sycromax. In my 2006 TDI I am using Redline 75w90 with a oil additive called Power Punch. shifts way better with that combo then the factory oil.

 

[Yellowbeetle2004]

What tranny fluid to use?

What is the recommended tranny fluid to be used in a 2004 NB TDI PD that has difficulty primarily with downshifting and intermittent difficulty with shifting 1-2 and 4-5?

It has been suggested by posters on here to change the fluid due to difficulty with downshifting, but I do not know what the specs of the fluid are.

I was speaking with some friends who have other TDIs, and their suggestion was that the synchronizers may be going out. When I initially posted here on the forum, it was suggested that I check or actually change the tranny fluid instead.

I am a newby on here and just don't know what to ask for when I go to my local local fluids shop.

Any help will be grateful.

 

[randroz]

GM Synchromesh Fluid in my 2004 TDI PD

At 108000 miles started having trouble going to 3rd and down shifting to 4th gears. Just changed out trans. fluid with synchromesh (Pennzoil).
Problems seen to have gone away on 10 mile test drive, so far so good.

 

[docta96]

Update

7500 miles post transfusion with GM Synchromesh fluid, the transmission on my 2004 TDI with 208,000 miles is perfectly fine with none of the previou grinding symptoms on the 1/2 or 3/2 shift.....so far so good......

 

[halocline]

Out of curiosity, do you have the original camshaft in your 04 with 200K miles?

 

[docta96]

RE: camshaft

Yes, I have the original camshaft......quiet as it was when new.....10K-15K mile oil changes at dealership using VW spec oil.....replaced original brakes at 112K miles with VW OEM; still on replacements; am on third set of tires since originals; battery is original; oil consumption is nil, clutch is original; dealership service at 100K and 200K miles; glow plugs replaced under warranty; have replaced two front wheel bearings as soon as they became noisy; no lost time service. Daily commute is 150+ miles; I use air cleaner elements from 2.0 gas turbo (has prefilter built in); dealer has complied promptly with all factory TSBs; averaging 44 MPG overall since new; never below 41 occasionally over 50 using mostly BP and Gulf diesel with no addatives ever; performed successful ventectiomy several years ago. This is an outstanding commuter car.