Hi Guys,

i have heard that this is common on the Polo GTI's, when you drive it hard and slam it into second, it makes a horrible sound (almost like its grinding, but its not), does not happen all the time, intermittent problem

any of you experience this?

i had this problem on my jetta 5 tdi, my colleague has it on his golf tdi and another colleague has it on his polo gti. wonder whether that is normal since so many ppl are experiencing this. it annoying though and for me didnt happen with normal driving. only when i hooked it into second

Jueshen wrote:Hi Guys,

i have heard that this is common on the Polo GTI's, when you drive it hard and slam it into second, it makes a horrible sound (almost like its grinding, but its not), does not happen all the time, intermittent problem

any of you experience this?

Cable shift gearboxes dont generally like to be slammed into gear, but I've heard of this problem before on the Polo GTi's.

It is a known problem for the 110kw / cable shift box. As mentioned, they don't like a snap shift, also they recon a decent synthetic oil in the g/box makes a difference. Personally, I'd aim for a more precise shift into second....

hey guys, im struggeling with the same bloody problem. with the 30 000 km service, they changed the oil in the gearbox, and it made a huge difference, but after about 5000km it started doing it again, especially when u have a dice and slams it into second gear !. (lost a dice to a opc corsa due to that f@#$%^'ing gearbox) im still not sleeping over it !!, but im taking it back om monday, hopefully it will do the trick !!!!

yeah few guys have had this issue and complained to the dealer....dealer got a new synchro and repalced with no issues now

I had the same issue...VW has however got a fix as it is a known problem. I even spoke to the service consultant and he told me they got the fix and manual on how to fix the problem.
The problem is sorted out now, but it left me damaged as I still change as if there is a problem...if you know what I mean.

Thanks for the responses

took my car for a few runs this morning, and i dont seem to be having the issue anymore, maybe my changing is more accurate, i have no idea!

should i still take it in?, i dont often run it hard

thanks

Jueshen wrote:Thanks for the responses

took my car for a few runs this morning, and i dont seem to be having the issue anymore, maybe my changing is more accurate, i have no idea!

should i still take it in?, i dont often run it hard

thanks

bud, my colleage at graaf... has the same problem with his Polo GTi... its currently at VW and they fixing it under Warranty..
not sure exactly what the problem is thou..

it might be a good to have it checked out..

Hi Jueshen,

I've got the same problem on my PGTI...Only seems to happen on when i'm changing on high revs

Car was booked with VW last week to check the gearbox - they changed the gearbox box, but that didnt help.
They say the gearbox needs to be repaired - car is currently with VW.
Seems to be a common problem with the PGTI...

If yur still having hassles rather have it checked out...

The car is under warranty
Get it fixed as it will get worse in the long run
Because it is in early stage the ring still has enough bite to slow the hub on normal shifts
When you shift hard/fast you need that instant bite and stop to allow smooth engagement of the gear and this is where the ring is not coping.
Its not a big repair get it fixed now as each time you grate it it is causing damage to the dogging teeth and hub etc

Cheers

Crash

eissh!

thanks guys, well i guess since it's under warranty i reather have it done none now, just such an inconvenience, any specific dealers that know what they are doing? dont wnat to have to take it back again and again or should i take it to the dealer i bought it from?. they better give me a loan car...

sup all,

so i left the office drive slow until the car was warm and then drove like a blerry madman to see if it grinds,

No more grinding!!! i dont know why but i guess its a good thing,

may b it has something to do with the wieght of the car, usually when i do race it i have about quarter tank and as i said befor it intermittently grinds maybe ( 1 out of 8 times) but since the last grind it doesnt happen any more even when the tanks on qaurter or full like it was today

Car is still under warranty till 2011 so i guess i'll have it checked anyway just out of curiousty at the next service, im just scared that theses service agents are going to break something else, while fixing the gearbox, the 1 thing i hate is inconvenience

will keep you all posted

and to the guys still having problesms, how often did u have them? and please let me know what the agents to fix it

Thanks

1. plolo GTi have 02j box and use castrol bot 150m(is a full syntetic 75w/90 oil comes in 500ml R80 exspensive need 500mlx4=2l)pleas do not use normal 75w/90 becaus oil must last life of the box/car and
2.02j box has a 3part sincro's 2nd gear has a outer sincro with inner ring and inner syncro cost R1100 if one gives K@k you will have grind in 2nd

as seen on fig no 16.17.18


Check inner ring for wear by pressing ring onto 2nd gear cone
and measuring gap "a" with feeler gauge. Normal dimension is .03-.05"
(.75-1.25 mm). Wear limit is .01" (.3 mm). See Fig


3.Can some one with pgti pleas put car in first ingage the clutch and release the brake and hanbrake on level surface and rev to limiter and check if car moves forward.What hapens on 2l16v with copper clutch and vr6 pressure plate the pressure plate resonace on high reves and touches the clutch letting car move forward can be same on pgti,but have heard some golf4gti have viscous clutch and not sure what pgti have.
If this hapens then when you in 1st and ingage clutch to select 2nd on high rev it's the same than changing without ingaging clutch

Hey guys

I had this problem...so let me make life a bit easier for you'll

You will need to install following parts from VW

02J 2nd gear grind fix ...
[2] - G-005-100-A1 - oil, .5 litr
[1] - 00076 - brake klee
[1] - 02J-311-239-J - synchr hub
[2] - 02J-311-247-C - synchr ring
[1] - 02J-311-261-K - 2nd gear
[1] - AMV-188-200-03 - seal comp
[3] - G-005-100-A1 - oil, .5 litr

Once installed, problem solved!!!

Hi guys.

It is adv to let them chainge syncro ring and gears.
New box can make the same.
They must first check box and see if the gear oil campaign is listed for the car.There is a anf out to say we must first chainge the gear oil to minr. oil from synthetic.

shoo, you guys are really clued up hey!

well i will be booking the car in on monday, i had it grind this morning!!

i just wish they could just change all the stuff that Huzidada had done, but they have to change the oild first apparently!

oh well, i guess procedures is procedure, i know i will take it back a second time round, but as long as it gest fixed

thanks all, really appreciate it

eish guys hows this for peace of mind

Went to VW Jan Smuts, explained the problem to them, and they said they have never heard of that problem before, but will get sum1 to check it out
!!

its like going in for heart surgery and the guy doesent know what he's looking for!!!

eventually made a booking at hatfield VW (bryanston) were i spoke to Morne ad he assured me they know what to do, but they most probably will change the oil first, depends if there is any damage in the box or not, and will test

Will keep u guys posted, taking her in monday morning

Hi Jueshen,

To put yur mind at ease - I got my PGTI from VW Hatfield(Big Thanks to Morne and Andrew) yesterday.
Had the same problem as yur PGTI...The car is now sorted
The car some how feels much stronger - nothing like when I 1st drove it out of the showroom.
Its like a little beast now

Any stock G5 GTI wanna take me on

Thanks Roms,

they changed the G Box oil on mine, havent had any issues yet. what did they do on urs??

Hi Guys,

While we on the subject of gearboxes and with all the gearbox gurus watching this thread, i have a small issue thats bugging me.
Its on my 04 132kw Golf (6spd box). Changing from higher gears to to 3rd, upon releasing the clutch there is a low pitch whine when the car slows on 3rd, and this is doing slow speeds. It only happens when the car is still warming up and only happens when releasing the clutch. It engages 100% upshifting and downshifting, and when the car is up to temp the whine goes away.

Anyone with any ideas. The car is coming up to its 90k service, maybe i should just ask the vw tech's to change the oil in the box 1st.

Appologies if i jacked the thread.

I have seen one or two boxs do that,[6spd]
Get it looked at as it will get worse and damages box.R16800.00 for recon and R33000.00 new.
Dealer prices.

I have seen one or two boxs do that,[6spd]
Get it looked at as it will get worse and damages box.R16800.00 for recon and R33000.00 new.
Dealer prices.

OMG

Ill def point it out to the vw guys when i take the cab in.

Golf 4 GTI 132kw 6spd fix


02M 2nd gear grind fix ...
[1] - 02J-311-251-J 1st gear
[1] - 02J-311-261-L 2nd gear
[1] - 02J-311-239-J synchr hub
[2] - 02J-311-247-C synchr rng
[2] - 02J-311-277-A synch ring
[2] - 02J-311-279 Outer ring
[1] - 02A-311-531-K reversgear
[2] - G-005-000 Oil-1 litr

shoo lots of G Box issues! anyhoo looks like the oil change on my G Box did not fix the issue---still grates!, made a booking for next week with Andrew... +-3 days, gonna miss her, BTW after looking at alot of Dyno results on worked PGTI's and stock ones, the stock pushes out +- 116 KW and 240 NM, can any 1 agree with me on that one?