1.9 TDI 5 speed shift issue.

[tank]

I have a 2000 Beetle with the 1.9 and a 5 speed manual. It started becoming hard to shift recently. It shifts fine in the morning and quickly fades. There are no gears grinding, but the smooth shift turns into a hard shift. Should I be start looking at the transmission fluid or the slave cylinder?

[kcfoxie]

Miles? The selection is easy but engaging is where it's "rough?"

[tank]

The mileage is 176,000. I bought I about a month ago and it worked fine for three weeks or so. It is the engagement that is rough. No problem with selection.

[kcfoxie]

Gear oil should be changed every 100k so that could be it; slave cyl could also be low on fluid...braking OK? Might need to flush the brake and clutch master cyls to ensure good pressure. May have a leak somewhere.

[tank]

I checked the brake fluid the other day and it was actually a little high. I am trying to find out what the previous owner was hiding. I knew it had to be something. I will change the gear oil and see if that eases the problem. Thank you.

[jason m]

i WOULD BET ON CLUTCH SLAVE AND MASTER CYL

[tank]

I changed the slave cylinder and the one I took off looked to be fairly new. When I put it back together the problem was worse. I can only put the car in reverse if the engine is not running. It will not go into any other gearseasily either. At idle with the clutch pedal to the floor it creeps back now. I am assuming that the master cylinder is the next logical step. Are they hard to replace??

[DZLBUG]

Its creeping with the trans in gear and the clutch pedal down? Pressure plate may be shot and the clutch not fully disengaging.

[tank]

I changed the master cylinder today and the creep is gone. It still will not go into gear though. Could this be caused by low gear oil? I'm stumped.

[tank]

I changed all the clutch cylinders and the clutch appears to be working. I changed the gear oil and it was good. It still will not go into gear while the engine is running. I am really confused because this wasn't this bad until I changed the master and slave. Could the shifter cables be out of adjustment, or is it time to take it to the shop??

[DZLBUG]

Time to replace the clutch, I would recommend a VR6/G60 SMF setup.

Sent from my DROID2

[tank]

I am confused as to the reason why the clutch could be out, but engage and disengage fine with the pedal. It just won't let me put it in gear. I would think that the clutch would slip or not engage at all.

[tank]

Where can I find the clutch set up you are talking about?

[DZLBUG]

Its not releasing fully so the input shaft is still spinning while you are trying to put it in gear.

www.idparts.com
www.boraparts.com
www.metalmanparts.com
www.worldimpex.com

Sent from my DROID2

[tank]

That makes sense. I just needed it to make sense in my head before I tore into it. Thank you so much for the information.

[h_2_o]

I am curious what gear oil you used, before you go doing a smf swap post the gear oil please. These transmissions are a little picky and if you have read over on tdiclub about fluid changes you will see that some fluids do what you are talking about.

[tank]

I used 75W90 gear oil. My wife talked to a bug mechanic today and he said $1150 to do the clutch and flywheel. He said they came from the factory with a dual mass flywheel and needed a solid. Is this on track, or am I being held over the coals a little more than I should?

[kcfoxie]

ummm my 2006 Jetta, purchased 2/07, needed a clutch at 31k miles in 7/07 and with a PERFORMANCE flywheel the total came to around $980 installed. Yeah I'd say that's a little high given that the 90HP unit doesn't need a 300ft-lb rated flywheel OR clutch like my chipped 06 TDI did.... at most, going factory (no reason NOT to) $600? I'm guessing but $1150...sounds like A LOT. You can get this done via TDIClub for less I feel.

[Smileybug]

The bigger question is did you use a GL4 or GL5 oil. GL4 is the only oil that should be used in these transmissions. GL5 is no good for them.

[h_2_o]

as the previous poster said which gear oil, these transmissions do not like all 75w90 gear oil, please give us the brand and type you used and that will help. I've seen regular 75/90 gear oil turn these transmissions into paper weights until they got it flushed out. so please brand and type.