Just want to say thanks for these videos. I'm experiencing a different issue with my 02B (something with the reverse system is clonking pretty bad) but nevertheless this has been helpful.
My pleasure. RU-vid doesn’t have enough content on 02A/02B boxes. I have a bunch of media from my rebuild that I still have to splice together and upload. Stay tuned…. Also, my clutch fork bent a few weeks ago and I have to drop the transmission again after only 4 months. Never ends…
Pleas share your wisdom as to the cause of this failure. My amateur understanding is that by lugging a diesel with lots of torque at low rpm in 5th gear when 4th gear should be selected, there is a chugging sort of hammering between splines. How many miles on this unit, and what part has been driven by you and if I may ask, could it be lugging? I greatly appreciate this video, and look forward to similar work on my T4 in changing the 5th gear ratio to .62 from something like .785 in a petrol ACU engine with cylinder head mods including thinner stemmed higher flow valves, and porting per David Vizard. Best regards!
Thanks for the comment. This was a "rebuild" (big emphasis on the quotation marks). I purchased it from a used parts dealer in the Netherlands in 2017, and personally have no idea how many miles it had on it at the time. All I did was fill it with oil and bolt it to the TDI that I was installing into my formally VR6 van. About a month into driving it, I stripped the teeth out on 5th gear. I'd say I might have been lugging it a bit much, because this was my first diesel vehicle, and I wasn't hyperaware of what kind of power the engine put out at such low revs. I replaced the 5th gearset with an 0.72 (if I recall correctly), and had zero issues after that. I did a full front suspension rebuild that required removal of the driveshafts, incorrectly torqued the inner joints to the drive flanges, the driver's side came loose, flung around, and ended up punching a hole in the case of the box. At this point, I found the outer (larger) input shaft bearing to be terribly worn as a result of swarf generated by the original 5th failure. This worn bearing had been causing a mysterious "clunk" hammer upon takeup/letting on and off of the throttle. Replacing the bearing carried me for another ~20,000 miles, and I also replaced the 5th gear with an 0.658 set at this time, where I also noticed that the splines had some abnormal wear. This most recent failure, in my opinion, was caused by a mixture of abuse by whatever European had this gearbox last, and whatever abuse was sustained under my ownership when I finished the van in early 2018. I was quite careful with applying too much throttle in 5th, especially at low RPM. These 4 cylinder TDIs have quite a lot of crankshaft "pulsations" or rapid acceleration/deceleration between strokes, which is why they also experience shearing of crank sprocket keyways when one doesn't retrofit a clutched alternator pulley. In the future, I will have no qualms about downshifting to 4th and running the engine up to very high RPM when climbing hills on the highway. I've been very good to this gearbox (as evidenced by the extremely low wear on the synchro rings), and I can afford to abuse gears 1-4 a lot more than I have. I really need to make a forum post about this rebuild. I have a lot of media and general information to share with the few who actually give a damn. It was a very thorough and expensive rebuild, and I am not a transmission shop by any stretch.
Bonsoir je possede un t4 syncro mes vitesse passe bien mais quand je veut mettre la 5eme elle s'enclenche mais rien ne ce passe quand je lache la pedale d'embrayage vous pensez que ce soit les pignons que vous montrer ?
