eszut
Active member
Last week the wife's 02 Jetta wagon ( 237K) miles would shift into 5th gear but the car responded like it was in neutral. Removed 5th gear cover to find that the 5th gear Selector gear to transmission shaft was stripped. So 5th gear was engaging, but was not able to transmit the shaft rotation to the the Selector gear and 5th gear set.
I was able to source a replacement selector gear from a Junkyard transmission (marked in yellow) and there was enough of the shaft splines left to engage with the replacemnet selector gear AND as an added measure I drilled (1/8 carbide bit) and pinned the Selector gear to the shaft 180 degrees apart. Cut off excess drill bit with dremel tool. Selector gear bolt and washer should retain the cut off drill bits in the shaft and gear.
5th gear is working again (will report back mileage if/when fails). Replacement 02J gearbox purchased and standing by.
The big Question I have is what or Why would cause the interference fit (needed a gear puller to remove the junk yard selector gear)Shaft splines to Selector Gear splines to wear out. (Please don't say gear oil) As I have replaced gear oil with VW gear oil (G 070726 A2) at each 100K and when I pulled the 5th gear cover gear oil drained out not to mention NO room for gear oil in the splines when pressed together.
I suspect that the spline wear occurs not when 5th gear is engaged and under a load but when the car is being operated in the other gears 1-4 and the 5th gear is along for the ride not under a load and it starts a slight vibration and begins wear the gears more and more over time.
This thought makes me think one might want to remove cover and inspect shaft to selector gear splines for "play" and depending on severity apply "Loctite" retaining compound to eliminate the "Play" in the splines and OR drill and Pin.
THOUGHTS????
Please also note I did a Auto to Manual swap approximately 100K miles ago and do not know the mileage previously on the 02J prior to installation.
I was able to source a replacement selector gear from a Junkyard transmission (marked in yellow) and there was enough of the shaft splines left to engage with the replacemnet selector gear AND as an added measure I drilled (1/8 carbide bit) and pinned the Selector gear to the shaft 180 degrees apart. Cut off excess drill bit with dremel tool. Selector gear bolt and washer should retain the cut off drill bits in the shaft and gear.
5th gear is working again (will report back mileage if/when fails). Replacement 02J gearbox purchased and standing by.
The big Question I have is what or Why would cause the interference fit (needed a gear puller to remove the junk yard selector gear)Shaft splines to Selector Gear splines to wear out. (Please don't say gear oil) As I have replaced gear oil with VW gear oil (G 070726 A2) at each 100K and when I pulled the 5th gear cover gear oil drained out not to mention NO room for gear oil in the splines when pressed together.
I suspect that the spline wear occurs not when 5th gear is engaged and under a load but when the car is being operated in the other gears 1-4 and the 5th gear is along for the ride not under a load and it starts a slight vibration and begins wear the gears more and more over time.
This thought makes me think one might want to remove cover and inspect shaft to selector gear splines for "play" and depending on severity apply "Loctite" retaining compound to eliminate the "Play" in the splines and OR drill and Pin.
THOUGHTS????
Please also note I did a Auto to Manual swap approximately 100K miles ago and do not know the mileage previously on the 02J prior to installation.