So what goes wrong with the 'box?

6n2stan · Post by **6n2stan** » Sat Apr 20, 2013 8:54 pm

So I've collected Chazaxl's black 3 door today with the busted 'box. I've looked through the archive but there doesn't seem to be a definitive answer to the cause/causes of the failure. The rivets in the diff seems to pop up a bit like the mk4 golf problem but what else is it likely to be?

I'm going to rebuild this 'box myself slow time so it's not a rush job.

Thoughts running through my head are:

Lupo 6 speed; I appreciate the final drive is the same as a 5 speed but with closer ratios.

Or

Lupo 6 speed with Polo 1st through to 5th ratios with a diesel 6th for motorway cruising?

Or

Stick with standard 5 speed but uprate the weak bits (what are they?)

Or

Is there another 'box that'll fit? (4motion synchro anyone? Lol)

Cheers

Endi_GTI · Post by **Endi_GTI** » Mon Apr 22, 2013 3:06 pm

When I rebuilt my box I found that the (plastic) 5th gear needle roller bearing had given up and cast all its needles throughout the box. Luckily I diagnosed it quickly and barley drove it so I opened the box and re newed every single bearing with Timkin metal ones. The only other thing was a new selector arm seal and my box has done 30,000 miles now and still going strong.

The symptoms of my box going was a whirring in neutral and also difficult selecting 5th. Also when driving along and lightly pressing on the 1st gear syncro it would scream its head off.

I know there are other things that go wrong with these box's but in my case this was the problem. Also I can't stress enough how important it is to use the genuine oil. it is very much like p*** but does the trick. When i drained mine it was like someone had put tractor oil in to try and quieten it down

Post by **alexperkins** » Mon Apr 22, 2013 3:11 pm

A very useful post here...

http://www.uk-polos.net/view ... 80#p385080

6n2stan · Post by **6n2stan** » Mon Apr 22, 2013 8:20 pm

Cheers Endi, Chaz did say bits of metal dropped out with the oil so it's the 5th gear bearing or the diff rivets I guess.

I did read that thread Alex, thanks. I'll refer back to it as I go along. I take it OEM parts aren't the way forward then?

I've just gotta finish building my lads climbing frame to free up some garage space then I'll get on with it!

6n2stan · Post by **6n2stan** » Sat May 04, 2013 9:34 pm

Endi_GTI wrote:When I rebuilt my box I found that the (plastic) 5th gear needle roller bearing had given up and cast all its needles throughout the box. Luckily I diagnosed it quickly and barley drove it so I opened the box and re newed every single bearing with Timkin metal ones. The only other thing was a new selector arm seal and my box has done 30,000 miles now and still going strong.

The symptoms of my box going was a whirring in neutral and also difficult selecting 5th. Also when driving along and lightly pressing on the 1st gear syncro it would scream its head off.

I know there are other things that go wrong with these box's but in my case this was the problem. Also I can't stress enough how important it is to use the genuine oil. it is very much like p*** but does the trick. When i drained mine it was like someone had put tractor oil in to try and quieten it down

Endi,

I've just looked into that Timkin company. Did you just measure up your bearing requirements and order them or find an outlet and go with the old parts?

Also, is there any special tools needed like a slide hammer or bearings presses? I've never had a gearbox apart before so I don't want it to dissolve before my eyes as I open it up!

Endi_GTI · Post by **Endi_GTI** » Mon Jun 17, 2013 10:43 pm

Hello mate,

Sorry just seen this post. have been away at sea for a long time. I recall asking a local company to source them for me. Think it was DJ Transmissions in Plymouth. My Uncle sourced all the parts for me but yes I would imagine they used the VW parts program to get the equivalent.

Hope you have sorted it now any way?

6n2stan · Post by **6n2stan** » Tue Jun 18, 2013 8:32 am

Hiya mate,

I took the 'box to a local specialist in Lincoln for some advice, they said they'll open it up for free and diagnose it.

All the common faults were fine (5th gear bearing, diff etc). However the lay shaft bearing had collapsed distroying most things inside. I decided to have them repair it as I had to have a complete new lay shaft but using my gears which requires a 30 tonne press etc! I've had an uprated diff in too which has a bolted crown wheel instead of the cheese rivets that normally come from VW.

The 'box is back on, I've just got to fit the drive shafts and shift linkage. Once its on the road, I'll take my daily off as the release bearing is louder than the engine! Another 'box/clutch off/on job

Endi_GTI · Post by **Endi_GTI** » Tue Jun 18, 2013 10:33 pm

Sounds good man. Glad you got it sorted. So it seems even more problems with these chocolate boxes. Ahh well ill just wait for my next pop

joe2612 · Post by **joe2612** » Wed Jun 19, 2013 10:01 pm

Mine has been making some funky noises recently

6n2stan · Post by **6n2stan** » Thu Jun 20, 2013 10:33 am

What noises mate?

In gear? Which gear? or neutral?

joe2612 · Post by **joe2612** » Fri Jun 21, 2013 2:16 pm

Well fourth mainly, seems to be noisier than it once was. I know polo gearboxes are a bit noisey anyway!

slarner · Post by **slarner** » Sat Jun 22, 2013 9:17 pm

My box went a while back. It was making a horrible noise in every gear. Like something was caught round the insides. Bear in mind who ever done it before me put diesel gears in it and it destroyed them!

I got a recon box been in now 20,000 miles it has been abused everyday seams to still be going strong. But the drive shaft seal has gone and 5th gear has whined ever since it was fitted back in.

6n2stan · Post by **6n2stan** » Sat Jun 22, 2013 9:32 pm

joe2612 wrote:Well fourth mainly, seems to be noisier than it once was. I know polo gearboxes are a bit noisey anyway!

That could just be the synchromesh on that gear. If 2nd was bad as well as 4th, then it could be layshaft issues. TBH the gearboxes are generally sh!t throughout bless them

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