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 Post subject: Gearbox problem
PostPosted: Wed Dec 09, 2015 12:25 pm 
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Joined: Sat Oct 04, 2014 6:08 am
Posts: 87
Location: porto
hey guys, today when exiting the car at a park i couldnt insert 3rd and 4th gear. Only with a lot of effort the gear stick in place, but i needed to apply a lot of effort to exit the gear too. When i got home i disconnected the links between the box and the (piece where is the gear knob)

And when going through gears i noticed that 3rd doenst linked correctly, at least it doenst sound like it was perfectly connected, when applying a lot of strength it finally connected and in that moment it was pretty hard to remove from 3rd gear. What can be the problem?

I have another gti box but it whines like heel in 1st and 2nd gear, but it whines until 4th i think

Thanks


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 Post subject: Re: Gearbox problem
PostPosted: Wed Dec 09, 2015 10:30 pm 
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Joined: Sat May 18, 2013 12:48 am
Posts: 170
Location: San Diego CA
If you took of the linkage apart from the box then you can eliminate a problem with the rods. Really the only way to see whats wrong is by opening it. Could be anything really. If you have a spare one swap them and open her up, its fun to work on them, nice and simple, make sure you buy a kit, once there might as well replace synchros bearings and seals. If you want to change your Ring pinion ratio now is the time!


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 Post subject: Re: Gearbox problem
PostPosted: Thu Dec 10, 2015 7:06 am 
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Joined: Wed Jan 29, 2014 1:18 am
Posts: 212
Location: Slovenia
if you can be a day or two without car buy new seals, bearings and i recommend synhrons too.. then took both gearboxes apart and use best parts of each to build nice gearbox that will work for some time..
it is possible that on your current gearbox there are some worn out/broken/bent parts in shifting mechanism inside gearbox, and on your other gearbox it's most likely bearing failure..

but before you put your gearbox off car, put shifting rod off gearbox, loose 3 bolts that hold those steel balls under springs in place and try shifting.. it should be much softer now.. check those balls for damage too.. if all looks ok and it's still hard to shift then problem is inside gearbox..


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 Post subject: Re: Gearbox problem
PostPosted: Thu Dec 10, 2015 4:32 pm 
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Joined: Sat Oct 04, 2014 6:08 am
Posts: 87
Location: porto
Ty both! How much the ring pinion ratio costs? What would be the difference? What about getting a longer 5th gear?

I will check tomorrow for that, ty lukak, but why do i need to put shifting rod off gearbox??


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 Post subject: Re: Gearbox problem
PostPosted: Thu Dec 10, 2015 6:52 pm 
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Joined: Wed Jan 29, 2014 1:18 am
Posts: 212
Location: Slovenia
gti have 4.1 fd. with a little luck you may find 4.39 from 1.0 cabrio i think or 4.44 from daewoo matiz (1.0 engine, 2000-2005 year for eu market, not sure for others)
if you want longer you can use it from 1.3 8v (around 3.7 i think)

for 5th gear you can use it from 1.3 8v or 1.0 3cyl but then you get pretty big difference between 4 and 5 gear.. i use it anyway 8)


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 Post subject: Re: Gearbox problem
PostPosted: Thu Dec 10, 2015 8:30 pm 
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Joined: Sat Oct 04, 2014 6:08 am
Posts: 87
Location: porto
What's best/fastest? daewoo?

Its pretty hard to find the 1.3 8v here


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 Post subject: Re: Gearbox problem
PostPosted: Fri Dec 11, 2015 7:20 am 
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Joined: Wed Jan 29, 2014 1:18 am
Posts: 212
Location: Slovenia
most close ratio of those is 4.44 but 4.39 is almost the same.. if lucky you can find those sometimes on forum for about 250eur/usd + shipping

the one from 1.3 8v is longest and best for highway use..


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 Post subject: Re: Gearbox problem
PostPosted: Sat Dec 12, 2015 5:39 am 
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Joined: Sat Oct 04, 2014 6:08 am
Posts: 87
Location: porto
So closer ratio makes the car reaching the speed, longer ratio makes the top speed higher?


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 Post subject: Re: Gearbox problem
PostPosted: Sat Dec 12, 2015 10:38 am 
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Joined: Wed Jan 29, 2014 1:18 am
Posts: 212
Location: Slovenia
closer ratio mean there is less difference between gears.. so better acceleration and lower top speed

for info:
195/45/15 tyres (similar to 185/50/15, 185/55/14, 175/60/14) at 7500 rpm by gear in km/h

4.44 fd with gti gearset:
52-94-129-172-204 (5th at 3000rpm is 82)

4.44fd with gti gearset and longer 5th gear
52-94-129-172-234 (5th at 3000rpm is 94)

stock gti gearbox:
56-101-140-186-221 (5th at 3000rpm is 88)

longest gearbox, from earlier (mk2,3) 1.3 8v (about 3.5 fd)
65-118-175-244-295 (5th at 3000rpm is 118)

my frineds gearbox for racing with 5.45 fd and custom 4th and 5th gear:
42-76-105-126-145 (5th at 8500rpm (rev limit) is 164)


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 Post subject: Re: Gearbox problem
PostPosted: Mon Dec 14, 2015 6:00 pm 
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Joined: Sat Oct 04, 2014 6:08 am
Posts: 87
Location: porto
Ty lukak!! I dont know why since the spring and the steel balls were undamaged, anyway when i re intalled them in my car i no longer had the problem. Dont know what caused it though

Here is the selector i changed, but didnt did the trick but there was defenitely less travel beetween gears. The links are in perfect condition in this selector

http://i.imgur.com/TZ4yBGR.jpg

http://i.imgur.com/GgjsoyZ.jpg


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