Gear selection issues

G

GordOfSomerset

Member
Hi Guys,
I’ve been reading other posts so have an idea of what this could be, but thought I’d double check.

I have a 2002 1.4 TDi and for the most part it is a wonderful car, except now he’s being a pain with gear selection. The issue seems to be mostly with getting into first or reverse. My wife is moaning non-stop about it so I now need to do something.

I’ve read it could be a gear adjustment cable or the gearbox of clutch? Is the cable an easy thing to DIY? Funds are limited right now as I’ve just bought a house and that is draining my funds.

Thanks guys. I love my A2 and want to keep it going as long as possible, but at 160k miles, I want to make sure I only do economical repairs. He got through the last MOT with no problems so I think there’s more life in him.

Cheers
 
If the cables are properly goosed then that is a problem as they are currently unavailable new and rare second-hand. WOM are working on finding a supplier to custom-make them but as far as I'm aware that isn't close yet.

Assuming the better-case scenario that it is basic adjustment of the cable end positioning that is the problem, this is eminently do-able. There are a pair of sprung grips that lock onto the cable ends and transmit movement of the cables into movement of the shift mechanism. Fore-aft movement of the gearlever equate to a rotation (clockwise / anticlockwise) of the shifter. Left-right movement of the lever is converted to vertical movement of the shifter in and out of the gearbox.

Try searching "gear cable adjustment" in the search dialogue box above ; also look up videos on dieselgeek's channel on Youtube as that has a good general explanation of all the components that comprise the gear selection mechanism as well as those that wear and contribute to sloppiness in shifting and so on.
 
My gear selection was a bit notchy, particularly 3rd gear, if rushed.
Changed the gearbox oil, that made it better.
Then I lifted up the gear stick gaitor and the rubber under part under and found a build up of rubber particles around the gear stick ball. Hoovered them out and sprayed some WD40 in and selection is a lot smoother.
I've now got some lithium grease to spray in, and hopefully it will be better still.
 
Thanks guys, that’s really helpful! I’ll try the obvious things first and then get to the more complex, but will look at those videos. I’ll tell my wife to drive the other car for now so that will give me some peace for the time being.

I don’t contribute much (or anything, being honest), but I love this group
 
Quick update. I drove the car myself today (40 min drive) and it was horrible. Could barely get it into first or second, and reverse was a pipe dream.

After the drive I tried the simple thing of cleaning out any detritus from under the gaiter, and used some white lithium spray grease. No joy.

Then I turned to the video that had been mentioned about adjusting the cables. Literally a five minute job, and I now have all my gears again and the joy of driving my A2 has returned!

Thank you all for your input and advice. Huge weight lifted
 
check the gear selector tower bearings, see if the gear selection shaft has any sideways movement.if it has it can make gear selection difficult. it's an easy job to replace them.
 
I think I have mentioned before, my third gear was impossible, Changed tower bearing & 1.9 liter gear oil now its 99%, the bearing had ZERO balls left, an hour labour plus £20 gear oil, plus £17 bearing & rubber sill. The oil was like red smelly water.
 
What lubrication is recommended for the gear selector cables?
I ask as today I went to drive the car, reversed out of the drive fine, up the hill 1st and 2nd gear then into 3rd, shortly after I could not get 1st, 2nd or reverse.
Managed to nurse it home in 3rd luckily limited traffic around.
The gears on the left are selected by just one of the cables operating? Seemed the tower mechanism was gunked up and stiff. Got it working again, then a liberal spray of AC90 (far superior to WD40 and cheaper) and all gear selection is excellent 👌
I had previously used lithium grease but wonder if that had dried up and actually not been so helpful in keeping the selector tower motion slick?
 
Evoman said:
What lubrication is recommended for the gear selector cables?
I ask as today I went to drive the car, reversed out of the drive fine, up the hill 1st and 2nd gear then into 3rd, shortly after I could not get 1st, 2nd or reverse.
Managed to nurse it home in 3rd luckily limited traffic around.
The gears on the left are selected by just one of the cables operating? Seemed the tower mechanism was gunked up and stiff. Got it working again, then a liberal spray of AC90 (far superior to WD40 and cheaper) and all gear selection is excellent 👌
I had previously used lithium grease but wonder if that had dried up and actually not been so helpful in keeping the selector tower motion slick?
Click to expand...
Has a selector cable snapped / broken?
 
Well no because all operating perfectly well again after freeing it off and then lubricating with AC90 spray. So I assume 'gunked' up in the tower mechanism caused the selector movement to be restricted.

Curious what lubrication folks recommend for the tower selector where the cables connect?
 
The replacement of the gear change tower bearing is one of the most cost effective repairs you can do on a TDi. The part is around £30 inc a new seal. The job will take a relatively novice mechanic a couple of hours. Change. the gearbox oil at the same time, 2 litres is all you need. If you can get something down the cables and lubricate the ball and socket at the base of the gearstick then it will transform the car. I have had made some brass sleeves that replicate the rather flimsy originals but yet to trial it. Watch this space...
 
You must log in or register to reply here.
Back
Top