Transmission cover leak

[WantingaTDI]

The transmission cover on my MKIV Golf is leaking. I touched it with a screw driver and created a very pronounced hole. Is this common and, where can we replace the transmission cover cheaply? I found this for 70 from IDI parts:

02J Transmission Cover

Transmission cover with magnet on 02J manual transmissions.The 02J is the stock transmission in A4 platform 5-speed TDIs....

www.idparts.com

 

[Brett San Diego]

You can probably find one on ebay pretty cheap. You'll want the gasket, too. Change it yourself. Five 10 mm bolts. 7 ft/lbs. Looks removable without having to move the transmisson, but I'm not 100% sure. I've just rebuilt my 02J, but I don't have it back in to see what clearances are like for removal of the cover. From your pic, it looks doable. You'll probalby have to unbolt the power steering hose retainer so you can move it out of the way.

You don't have to drain the transmission. The 5th gear compartment that this cover encases does not have a lower port into the main galley of the transmission, so all the gear oil sitting below the level of the ports into the 5th gear compartment will stay in the transmission housing (which will be all or nearly all of it).

Brett

 

[csstevej]

Yeah try a salvage yard , and it can be changed while in the car with no issues.
I’d also replace the fluid with fresh oil while in there . If you do , make sure you can remove the fill plug first before you drain it.

 

[Gvr]

I would also recommend you replace the gear oil if it hasn't been done in a while, it looks pretty dirty.
You could also fill through the speedometer gear hole, 22 mm nut, should come easy as it is plastic. Pour in 2 liters of gear oil and call it a job..

 

[csstevej]

You could also fill through the speedometer gear hole, 22 mm nut, should come easy as it is plastic. Pour in 2 liters of gear oil and call it a job..

Damn….. never thought of that ! Nice .

 

[Nuje]

Yeah - totally agree! I've always hated the "fill until you start spilling" methodology - definitely gonna go that route next time.

As for the cover - it's the same on a 02J for TDI as a 02J for gasser; so if you have a scrapyard nearby with any VWs, you don't have to be fussy about what engine it's mated to.