gear box crunch

since iv had my 1.8 clipper iv noticed if i got 1st to 2nd at a normal sort of speed it will do  crunch but if i do it slowly its fine…..mot said there a slight leak from box could it just be low on fluid??

Common problem to have a crunch between 1st and 2nd changing the gearbox oil will help and hopefully stop it getting any worse.

Gearbox oil is very often over looked till there is a problem with the gearbox I change my gearbox oil every 60,000 miles as it's a straight forward job and the cost of oil is alot cheaper than rebuilding a gearbox.

Great site on everything you ever wanted to know about the gearbox.

Welcome to BrokeVW.com

If there is a small leak it will be worth keeping an eye on it and the oil levels as if the oil gets to low the car will start to jump out of 5th gear and eventually you will wreak the gearbox.

I had a leak for about 3 years and just had to top up the oil every 6 months till I replace the drive shaft flange seals which is where they normally leak.

I've switched over to fully synthetic and it's helped my 2nd gear crunch when the gearbox is cold and the gear change is alot smoother, I still don't change from 1st to 2nd quickly when the gearbox is cold as it will crunch if to aggressive but it's fine once warmed up.  

http://www.eurocarparts.com/ecp/c/Volkswagen_Golf+Cabriolet_1.8_1989/p/car-accessories/engine-oils-and-car-fluids/car-tranmission-oils/manual-transmission-fluids/?522776022&0&cc5_868

2 bottles is plenty enough and euro car parts are always doing a sale so find the current promo code to get it cheaper.

Tool I use to undo both the filler and drain plugs, make sure you can undo the filler plug before draining the oil and if the plug is starting to round off buy a new one they are available from VW for a couple of £'s

1st one I found so shop around incase you find it cheaper.
http://www.ebay.co.uk/itm/Volkswagen-Gearbox-17mm-Hex-/332093663329?hash=item4d52532861:g:EQ8AAOSwpzdWq37n
 

Wow what a reply! Thanks for that I'll add it to my list of things I want todo when it gets abit warmer haha

I 2nd what Mark says about the oil. I changed mine last year and I drained out less than a litre of very dirty oil when there should be 2 litres and like Mark says it's an easy job to do. The difference it made to the gear change was amazing and the gearbox feels very smooth. I still get a slight crunch when the gearbox is cold but once warmed up it's good.
Just out of interest mark1gls what are the drive shaft flange seals like to change? I've got a slight leak that looks like it could be coming from that area so I'll have to check it out.

It's not to difficult if you have the right tools, there is a guide on the brokenvw web site .It is possible to change change the seal with the gearbox on the car and I've done it twice with the gearbox on a car and once when the gearbox was off the car and it's alot easier on your neck and back with the gearbox on the bench!

I have a home made tool to hold the flanges on but I recon you could just have a straight bar on the top and not the boxed section you can see on my tool.



The hardest bit is getting the circlip back on and in the groove, it keeps springing off the circlips pliers, I also found the 1st time I did it I had screwed in the tool to far into the flange and it would not go all the way in so the circlip would not go far enough on.

Don't forget the drain the oil before removing the flange as I found out it will pour out other wise.

Screw driver the prise out the old seal and I used the old seal to protect the new seal as I tapped it in and a little smear of gearbox oil over the seals help them slide in.

Time I changed them with the gearbox on the car and on axel stands, it's tight but there is just about enough room



You do need to move the drive shafts out the way by either undoing the bottom ball joint or undo the strut from the hub as I found I could not move them away from the flange with the suspension attached. I've changed mine when replacing the outer CV boots so the drive shaft is completely out of the way.
I also painted a white mark on the flange and CV joint so I put it back together in the same place.

Kit I used.
http://www.ebay.co.uk/itm/VW-GOLF-MK1-MK2-CADDY-PICKUP-GEARBOX-DIFFERENTIAL-FLANGE-SEAL-KIT-C540-/200949249882?fits=Model%3AGolf&hash=item2ec982375a:g:ekUAAMXQ01tRSzhO
 

Found some better pictures when I changed the seal on my Mk1 Scirocco, I had a nightmare getting the seal out on 1 side, I had to use a dremil tool and carefully cut a couple of slots in the seal to prise it out, other side no problem and the 2 other times it;s been straight forward.

Drive shaft bolts lose, the oil had worked it's way into the CV boot, that's the oil you can see dripping out.


Ready to remove the seal.


Having trouble with the seal!


Hour later it was coming out..




All cleaned up.


New seal tapped in place.


Tool to fit the flange in.


Time to fit the new dust seal.


All back together.

Thanks Mark, that is a good description. I guess it will have to go on the to do list nut as it's quite involved I think some proper investigation is needed.

I waited till I had the time and other jobs to do, just keep an eye on the gearbox oil. My drive at home has a slight slope so I would check mine after work as the car park was level, you can turn the wheels full lock left and gain access to the fill plug, remove the plug and top up, you can check the oil level with out needed to jack up the car as it's meant to be level and have a cold gearbox. I did this for 3 years till I got around to it..

I go to the Home Repair Store and Get PVC pipe Connectors in the size of the Seal I am trying to install.

Works really well.



You can use a 3 finger pulley tool to compress.


Or my Favorite a Ford Ignition Switch tool sprung out a bit.



The original 17mm bolt and 2 nut removal tool, I have since acquired the correct Allen.


Here is the reason it was leaking.  The CV broke and hammered the shaft, it took me about an hour to get the clip out.  Once I got the Seal out, I noticed that the
inner race was broken…..


I was thankful I had a spare Bellhousing…  Gotta Love Frankenautos.