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Mk5 gear box trouble - please help!

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Mk5 gear box trouble - please help!

Postby Davidclarke1 » Thu Mar 22, 2018 10:43 pm

Hello folks, I've had a sudden issue with my Mk5 smiley (1999) manual gear box. Its the version where the gear box can be accessed in part by removing the gear lever from above. It felt a bit rocky for a while, then the other day it just started refusing to go into any gear. I got it home but can't work out what the problem is likely to be. With the engine off, it goes into all gears very smoothly, even without the clutch depressed - but as soon as I start her up she won't go into any - or at least not without horrid grinding. There is good resistance in the clutch, and if I get her into gear, she will pull away, even in fifth. Should I be topping up gear oil (I put 500ml in but it seems not to have made a difference), thinking about taking gearbox off to get at selector, or am I just the owner of a knackered gear box? All advice very welcome! David
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Re: Mk5 gear box trouble - please help!

Postby Altransit » Thu Mar 22, 2018 11:12 pm

I believe that if it goes into gear without the engine running, but not with it running, you're looking at a clutch problem.
Possibly a damaged centre plate :idea:
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Re: Mk5 gear box trouble - please help!

Postby Noctule » Fri Mar 23, 2018 12:34 am

Had a similar-sounding problem a few years ago... the spigot bearing cage had collapsed which in turn took out the damping springs in the clutch. I could set off in most gears, but changing gear on the move was a pain. Luckily it was motorway most of the way home.

If you can, get 'box out and check the clutch and spigot bearing.

Mat
2000 Mk5 HiCube self-build camper
- 2.5tdi 4EA with EPIC-to-Bosch conversion
- DRW with 16" rims
- Mondeo instrument cluster
- Lunar Meteorite interior

2006 Mk7 115t350 van (cheap tax tramp)

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Mk5 100 swb Custom
Mk5 190 lwb x3
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Re: Mk5 gear box trouble - please help!

Postby Chug » Fri Mar 23, 2018 1:16 am

Before you pull the gearbox out, If you haven't had any other clutch/gear change problems recently its probably a clutch cable/adjustment problem, check if its frayed at either end, adjust the cable if its got the adjusting type cable pedal quadrant, if its fitted with the self adjusting ratchet type cable quadrant, inspect the ratchet to see if it's slipped on worn teeth, see if you can move it along a tooth or two.

another possibility is the clutch fork has bent.
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Re: Mk5 gear box trouble - please help!

Postby cherniy_chack » Fri Mar 23, 2018 8:31 pm

First, inspect the clutch cable, then under the car-fork (lever) clutch.
On cars in 1999, usually a pedal without a ratchet.
Next, remove the gearbox from the machine.
An autopsy will show.
Most likely, the "clutch basket" is faulty.
Broken or worn petals of the diaphragm coil spring.
Davidclarke1 ,when you find out the reason for the failure of the gearbox, write here.
It will be interesting for us to find out.

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Re: Mk5 gear box trouble - please help!

Postby bobbari123 » Sat Mar 24, 2018 8:52 am

Hi.
I had exactly same problem.
In my case it was a cracked clutch fork.
I suggest that you go under the van and try to move that fork with your hand.
You can recognize that part easily , just follow clutch cable, it mounts to that fork.
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Re: Mk5 gear box trouble - please help!

Postby Davidclarke1 » Sat Mar 24, 2018 4:59 pm

Great - thanks all - I'll get cracking on those tests and will post results!
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