Pops out of second gear - hack that is working

[markd89]

Bus transaxles are spendy to rebuild. I have a TDI engine from a 97 Passat and have more money and hassle invested in the Trans than I am willing to admit. I don't abuse the trans but don't baby it either.

A couple of months ago, it started popping out of second gear when driven very lightly (i.e. not decelerating, not accelerating). This would be usually when I am driving up to a stop sign or following someone moving slowly. It's intermittent and happens maybe 25% of the time in that scenario.

My bus mechanic guru told me that this has to be something internal and not in the linkage.

I found that I could prevent the problem by keeping a finger on the shifter, but that's just not convenient in all scenarios and sometimes I would forget.

I made the following ugliness with a piece of aluminum, 3 strong magnets and JB-Weld. It's positioned to grab on to the shifter when it's in the 2nd gear position. It provides just enough hold to prevent the pop out of gear issue and otherwise is transparent to the driving experience. A side-effect is that it will also grab when in reverse. That's not desired but not problematic either.

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78 TDI Sunroof Bus
Los Angeles

[[email protected]]

Start saving for another trans, or rebuild. Popping out of gear 99% of the time is the engagement drive teeth on the gear itself are worn. If that is the case, it will only get worse to the point popping out regardless of what pressure is attempting to hold it in gear. Another thing to consider is that while pressure is being put on the shifter, it is causing unnecessary wear on the 1st-2nd slider, and the shifting fork.

[skills@eurocarsplus]

on the bright side, your wiring is very well sorted
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[vwwestyman]

Well, I will have to say I understand the wiring stuff.

I've cleaned mine up quite a bit from before, but my bus has felt like some kind of experiment for several years now, with originally just trying to get it on the road and then making things nicer and more clean and all that along the way. So I get it.

Haven't you already had your trans rebuilt once to go with the TDI?

Only time will tell if my newly rebuilt trans will last this time around with the supposedly stronger gears and such. But I think it is becoming clear that the old 091s just don't like the TDI motors all that well. I'm hoping that this current rebuild will last long enough for some kind of breakthrough, such as somebody starting to manufacture all-new, tougher parts (or a whole new trans), or really great CV joints that will allow the flipped Passat trans to not have to mount so low, or something like that.

If it goes out again and there aren't any of these things by then, I may have to start thinking about other options altogether. Sorry this is going on!
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Dave Cook

President, Wild Westerner Club

1978 Champagne Edition Westy, repowered to '97 Jetta TDI
1973 Wild Westerner
My Thing

[markd89]

[markd89]

[markd89]

[alaskadan]

I wouldnt go so far as to say vanagon people do ok with TDIs. Theres been plenty of trans destruction over there too . No personal experience, but i read about it.

[sodbuster]

Do this if you must but save your pennies. There will come a point (and it may come sooner than you think.) that your "hack" will no longer cut it. The longer you wait and the worse it gets, (and it will get worse.) it will only cost more money.